Ford - Expedition 2wd - Workshop Manual - 2009 - 2009

Factory Workshop Manual Make Ford Model Expedition 2wd Engine and year V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations Antenna Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 13 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 14 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 15 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 28 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 29 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 34 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 Expedition 2wd Workshop Manual (V8-5.4L (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 35 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 45 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 46 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 51 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 Expedition 2wd Workshop Manual (V8-5.4L (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 52 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 Expedition 2wd Workshop Manual (V8-5.4L (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) Communications Control Module: Locations Accessory Protocol Interface Module (APIM) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 55 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 56 Communications Control Module: Locations Audio Control Module (ACM) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 57 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 58 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 61 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 62 Communications Control Module: Diagrams Audio Control Module (ACM) Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 63 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 64 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 65 Communications Control Module: Diagrams Audio Digital Signal Processing (DSP) Module Ford Expedition 2wd Workshop Manual (V8-5.4L (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 66 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 67 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 70 - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 71 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 72 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 73 Communications Control Module: Removal and Replacement Audio Digital Signal Processing (DSP) Module Audio Digital Signal Processing (DSP) Module Audio Digital Signal Processing (DSP) Module Lower Attachment Audio DSP Module Upper Attachment Audio DSP Module Removal Routing Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 74 Removal and Installation 1. NOTE: Module configuration is required when a new audio Digital Signal Processing (DSP) module is being installed. Upload the audio DSP module configuration information to the scan tool. 2. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control Module (ACM) See: Audio Control Module (ACM). 3. Remove the necessary attachments and move the center console 5 cm (2.0 in) towards the rear of the vehicle. 4. Disconnect the audio DSP module electrical connectors. 5. Remove the 2 lower audio DSP module nuts. - To install, tighten to 9 Nm (80 lb-in). 6. NOTICE: The audio Digital Signal Processing (DSP) module is heavy. Be sure to support the amplifier during removal, or damage to the vehicle may occur. Remove the 2 upper audio DSP module nuts. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the audio DSP module. - Route the audio DSP module down and towards the passenger side of the vehicle. 8. To install, reverse the removal procedure. - Download the configuration information to the audio DSP module. Audio Control Module (ACM) Audio Control Module (ACM) NOTE: Expedition without navigation shown, all others similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 75 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 electrical connectors and the antenna cable connector. 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 76 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. 2. Remove the front floor console. 3. Remove the 4 APIM screws and position the APIM aside. 4. Disconnect the Universal Serial Bus (USB) cable and the electrical connectors, and remove the APIM. 5. 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 Removal and Installation 1. Remove the floor console. 2. Remove the rear cupholder trim panel by pulling straight upward to disengage the clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 77 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 86 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 Expedition 2wd Workshop Manual (V8-5.4L (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 87 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 92 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 Expedition 2wd Workshop Manual (V8-5.4L (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 93 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 Expedition 2wd Workshop Manual (V8-5.4L (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 94 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 Expedition 2wd Workshop Manual (V8-5.4L (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 95 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 96 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 Expedition 2wd Workshop Manual (V8-5.4L (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 97 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 Expedition 2wd Workshop Manual (V8-5.4L (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 98 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 Expedition 2wd Workshop Manual (V8-5.4L (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 99 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 Expedition 2wd Workshop Manual (V8-5.4L (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 100 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 Expedition 2wd Workshop Manual (V8-5.4L (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 101 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 Expedition 2wd Workshop Manual (V8-5.4L (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 102 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 108 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 109 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 114 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 115 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 116 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 117 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 118 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 119 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 120 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 121 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 122 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 123 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 124 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 129 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 130 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 136 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 137 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 143 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 144 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) Entertainment System Control Module: Locations Rear Entertainment Module (RETM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 160 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 161 Entertainment System Control Module: Locations Audio Rear Control Unit (RCU) Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 162 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) > Page 165 Entertainment System Control Module: Diagrams Audio Rear Control Unit (RCU) Module Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) > Page 166 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 175 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 176 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 182 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 183 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 192 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 193 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 199 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 200 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 206 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 207 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 212 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 213 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 219 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 220 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 225 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 226 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 230 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 231 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 232 Parking Assist Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 233 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 234 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 235 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) - Expedition Removal and Installation 1. Disconnect the Parking Aid Module (PAM) sub-harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the sub-harness from the PAM. 5. Remove the 2 PAM bracket bolts. 6. Remove the PAM bracket assembly. 7. Release the module tabs from the bracket and remove the module from the bracket. 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 240 Memory Positioning Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 241 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 242 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 243 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 244 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. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed, it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Page 248 Power Seat Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Page 249 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations Power Trunk / Liftgate Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 253 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 254 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 255 Power Trunk / Liftgate Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 256 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Liftgate Latch Remote Control Power Trunk / Liftgate Control Module: Service and Repair Liftgate Latch Remote Control Liftgate Latch Remote Control Removal and Installation NOTE: The liftgate latch remote control is available with power liftgate only. 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. NOTICE: Be careful not to kink the liftgate latch actuating cable while disconnecting it from the latch. Disconnect the liftgate latch. 1. Release the liftgate latch actuator rod. 2. Disconnect the liftgate latch actuating cable. 4. Remove 3 bolts and position the liftgate latch remote control aside. - To install, tighten to 11 Nm (8 lb-in). 5. Disconnect the electrical connectors and remove the liftgate latch remote control. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Liftgate Latch Remote Control > Page 259 Power Trunk / Liftgate Control Module: Service and Repair Liftgate/Trunk Module (LTM) Liftgate/Trunk Module (LTM) Removal and Installation 1. Remove the rear quarter trim panel. 2. Remove the Liftgate/Trunk Module (LTM). 1. Disconnect the electrical connectors. 2. Remove the bolt. - To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. - Initialize the power liftgate. For additional information, refer to Power Liftgate Initialization See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Service and Repair/Procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations Auxiliary Step / Running Board Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 263 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 264 Auxiliary Step / Running Board Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 265 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 266 Auxiliary Step / Running Board Module: Service and Repair Power Running Board (PRB) Module Removal and Installation 1. Remove the LH B-pillar trim panel. 2. Disconnect the Power Running Board (PRB) module electrical connectors. 3. Remove the 2 bolts and the PRB module assembly. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module Seat Heater Control Module: Locations Rear Heated Seat Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module > Page 271 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module > Page 272 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module Seat Heater Control Module: Diagrams Rear Heated Seat Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 275 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 276 Seat Heater Control Module: Diagrams Dual Climate Controlled Seat Module (DCSM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 277 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 278 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 281 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 282 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 283 Seat Heater Control Module: Service and Repair Dual Climate Controlled Seat Module (DCSM) Dual Climate Controlled Seat Module (DCSM) Removal and Installation 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. NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Body and Frame/Seats/Service and Repair/Front Seats/Seat - Exploded View, Front. 1. When installing a new Dual Climate Controlled Seat Module (DCSM), carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Position the front passenger seat fully upward and remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. 3. Release the 2 tabs and slide out the DCSM. 4. Remove the DCSM. - Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. 5. To install, reverse the removal procedure. 6. If a new DCSM has been installed, carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 284 Seat Heater Control Module: Service and Repair Heated Seat Module - Second Row Heated Seat Module - Second Row NOTE: Bottom of floor console shown. Removal and Installation 1. Remove the front floor console. 2. Disconnect the 2 heated seat module electrical connectors at the bottom of the front floor console. 3. Remove the screw and un-hook the heated seat module. 4. To install, reverse the removal procedure. 5. Carry out the auto-configuration sequence to program the heated seat module for use with a dual momentary switch. - Start the vehicle and push the low button on either heated seat switch. - Operate the heated seats, monitor the indicators and verify the system is operating correctly in high and low. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 288 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 289 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 297 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 298 Electronic Brake Control Module: Diagrams Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 299 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 300 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 301 NOTE: On vehicles equipped with Roll Stability Control (RSC(R)), the ABS module and the Hydraulic Control Unit (HCU) are calibrated to one another. Do not swap ABS modules between RSC(R)-equipped vehicles. NOTE: On vehicles equipped with RSC(R), the ABS module is available separately from the HCU and should be serviced separately. However, if the RSC(R)-equipped vehicle requires a new HCU, then the ABS module and the HCU must be installed as an assembly. Make sure to use the most recently released service parts. NOTE: When installing a new ABS module/HCU assembly, it must be configured (either by download/upload or uploading the as-built data method). 1. Release the Air Cleaner (ACL) cover retaining clips and disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the ACL outlet clamp and disconnect the ACL cover from the outlet pipe. - To install, tighten to 4 Nm (35 lb-in). 3. Remove the 3 HCU bracket-to-frame bolts. - To install, tighten to 20 Nm (177 lb-in). 4. Disconnect the ABS module electrical connector. 5. Remove the 4 ABS module bolts and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 6. To install, reverse the removal procedure. 7. If installing a new ABS module on a vehicle equipped with RSC(R), configure the ABS module. 8. If installing a new ABS module on a vehicle equipped with RSC(R), calibrate the RSC(R) sensor. Connect the scan tool and carry out the IVD Initialization sequence. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 305 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 306 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 312 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 313 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 314 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 317 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 318 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 319 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 320 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 321 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 322 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 323 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 327 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC > Page 332 Control Module HVAC: Locations HVAC Module, DATC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC > Page 333 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC Control Module HVAC: Diagrams HVAC Module, DATC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 336 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 337 Control Module HVAC: Diagrams HVAC Module, EMTC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 338 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 339 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Service and Repair Exterior Lighting Module: Service and Repair Ballast Removal and Installation NOTE: Make sure that the headlamp switch and the ignition switch are in the OFF position. 1. Remove the headlamp assembly. For additional information, refer to Headlamp Assembly See: Lighting and Horns/Headlamp/Service and Repair. 2. Remove the 4 bolts and the ballast. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left > Page 351 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 354 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 355 Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 356 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 364 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 365 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 366 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 369 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 370 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 371 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data entry is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 devices are necessary to complete the configuration and turn off the flashing interior lights. 1. NOTE: This step is only necessary if the SJB is being replaced. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. A new SJB is delivered in a "manufacturing mode" with 7 pre-set DTCs. A successful configuration of the SJB, then a successful TPMS sensor training, then a successful self-test including the clearing of all DTCs is required in order to clear the 7 pre-set manufacturing mode DTCs. The 7 manufacturing mode DTCs are: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - 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) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the RH cowl panel side trim. 4. Remove the glove compartment. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 376 1. Position the SJB and install the 2 bolts. - Tighten the bolts to 2 Nm (18 lb-in). 2. Connect the 7 electrical connectors. 3. Install the RH cowl panel side trim. 4. Install the glove compartment. 5. NOTE: If the SJB is not being replaced, this is the last step that is necessary. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears the DTCs B106D and B2477. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the SJB. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. 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. 8. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 9. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO Power Distribution Relay: Testing and Inspection Relay - Macro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 382 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 383 Power Distribution Relay: Testing and Inspection Relay - Micro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 384 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 385 Power Distribution Relay: Testing and Inspection Relay - Mini ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 386 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 387 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 Relay Box: Locations Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 392 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 393 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 394 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 395 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 396 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 397 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 398 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 399 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 400 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 401 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 404 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 405 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 406 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 407 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 408 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 409 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 410 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 411 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 414 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 415 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 416 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 417 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 423 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 Expedition 2wd Workshop Manual (V8-5.4L (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 424 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 Expedition 2wd Workshop Manual (V8-5.4L (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 425 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts Engine Control Module: Customer Interest Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 434 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 435 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 440 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 441 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 447 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 448 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 453 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 454 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 455 Engine Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 456 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 457 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 458 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 459 Engine Control Module: Diagrams C175B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 460 C175B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 461 C175B Part 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 462 C175E Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 463 C175E Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 464 C175E Part 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 465 C175T Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 466 C175T Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 469 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 Expedition 2wd Workshop Manual (V8-5.4L (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 470 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) Removal and Installation 1. NOTE: Refer to Computers and Control Systems Information for correct Vehicle Communication Module (VCM) hook-up procedure. If servicing the PCM, connect the scan tool to the vehicle. Allow the scan tool to identify the vehicle and obtain configuration data. - All programmable module information will automatically be retrieved by the VCM. 2. Disconnect the battery ground cable. 3. Disconnect the 3 PCM electrical connectors. 4. Remove the 2 stud bolts and the PCM. - To install, tighten to 9 Nm (80 lb-in). 5. NOTE: If the Instrument Cluster (IC) or the PCM is being replaced (or both), the parameters must be reset in both modules or the vehicle will experience a Passive Anti-Theft System (PATS) no-start. This will occur even if the vehicle is not equipped with PATS. To install, reverse the removal procedure. 6. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 474 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 475 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Service and Repair Fuel Pump Control Unit: Service and Repair Fuel Pump Control Module Removal and Installation 1. Disconnect the fuel pump control module electrical connector. 2. Remove the 2 bolts and the fuel pump control module. - To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 483 Fuel Pump Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 484 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 488 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 489 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 494 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 495 Air Bag Control Module: Diagrams C310A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 496 C310B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 497 C310B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 498 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) NOTE: Seats removed for clarity. Removal 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. 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. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous Diagnostic Trouble Codes (DTCs) will result. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 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 NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is disabled. The RCM and Accessory Protocol Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 499 Interface Module (APIM) must be configured correctly to fully support 911 assist functionality. 1. When installing a new RCM, carry out the appropriate steps necessary for the PMI procedure. 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 Vehicles with center console 3. Remove the center console. Vehicles with bucket seats without center console 4. Position the carpet aside and remove the 3 RCM pushnut retainers and the RCM cover. All vehicles 5. Disconnect the small RCM electrical connector. 1. Push down to release the retaining tab. 2. While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1. Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2. Pull out and disconnect the large RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation All vehicles 1. 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. Install the RCM and 3 bolts. Tighten to 11 Nm (97 lb-in). 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 500 3. NOTICE: Putting the large Restraints Control Module (RCM) electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large electrical connector into the RCM. NOTICE: Do not push on the connector so that 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. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with bucket seats without center console 6. Install the 3 pushnut retainers and RCM cover. Vehicles with center console 7. Install the center console. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 501 All vehicles 8. 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. 9. If a new RCM was installed, carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. 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 air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. 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 a 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 memory DTCs from the RCM. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 507 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 510 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 511 Starter Relay: Testing and Inspection Run/Start Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 512 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 521 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 522 Suspension Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 523 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 524 Suspension Control Module: Service and Repair Vehicle Dynamics Module (VDM) Removal and Installation NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. NOTE: The Vehicle Dynamics Module (VDM) is mounted to the lower left side of the dash above the parking brake control. Disconnect the 2 VDM electrical connectors. 2. Remove the VDM bracket nuts and the module. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: The VDM is calibrated with information from the ride height sensors. A new or exchanged VDM requires that the LH and RH ride height sensors are calibrated and a Pneumatic Test is carried out. For additional information, refer to Vehicle Dynamic Suspension See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic )/Testing and Inspection Calibration Initialize System - Clear C1990 and C1991 DTCs. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 535 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 536 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 542 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 543 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 548 Heated Glass Element Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 549 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Quarter Window Open Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Quarter Window Open Relay > Page 554 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 557 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 558 Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 559 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 564 Wiper Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 565 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Hood Sensor/Switch (For Alarm): Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 571 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 572 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 577 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 578 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 579 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 580 Parking Assist Distance Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 581 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 582 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 583 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 584 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 585 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 586 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 587 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 590 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 591 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 592 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 593 Parking Assist Distance Sensor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 594 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 595 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 596 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Parking Aid Sensor - Front Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Front Parking Aid Sensor - Front Sedan Removal and Installation 1. Remove the front bumper cover. 2. Disconnect the parking aid sensor electrical connectors. 3. NOTE: Press the retaining tabs to release the sensor(s). Remove the parking aid sensor(s). 4. To install, reverse the removal procedure. - NOTICE: Paint the new sensor(s) with base coat and one coat of clear. Excessive paint film buildup may result in incorrect sensor operation. Using the scan tool, verify that the parking aid sensor PIDs read no object present, and that the parking aid sensor attenuation PIDs read between 0.8-1.6 ms. If the parking aid sensor attenuation PIDs do not read between 0.8-1.6 ms, the paint is too thick on the sensor(s) and it will be necessary to repaint the sensor(s) as required. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Parking Aid Sensor - Front > Page 599 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Rear Parking Aid Sensor - Rear Removal and Installation 1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor electrical connectors. 3. NOTE: Press the retaining tabs to release the sensor(s). Remove the parking aid sensor(s). 4. To install, reverse the removal procedure. - Using the scan tool, verify that the parking aid sensor PIDs read no object present, and that the parking aid sensor attenuation PIDs read between 0.8-1.6 ms. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 603 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 604 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 607 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 608 Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 609 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Hood Sensor/Switch (For Alarm): Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 615 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 616 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 620 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 621 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 624 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 625 Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 626 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Power Door Lock Switch: Locations Door Lock Switch, Passenger Side Ford Expedition 2wd Workshop Manual (V8-5.4L (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 631 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 632 Power Door Lock Switch: Locations Door Lock Switch, Driver Side Ford Expedition 2wd Workshop Manual (V8-5.4L (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 633 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 636 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 637 Power Door Lock Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 638 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 642 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 643 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 644 Power Mirror Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 645 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 646 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 647 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Remove the driver front door trim panel. 2. Remove the exterior mirror control switch. 1. Depress the locking tabs. 2. Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 652 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 653 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 654 Power Seat Motor Position Sensor: Locations Height Sensor, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 655 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 656 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 657 Power Seat Motor Position Sensor: Locations Height Sensor, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 658 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 661 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 662 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 663 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 664 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 669 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 670 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 671 Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 672 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 673 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 674 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 675 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left Power Seat Switch: Diagrams Seat Control Switch, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 678 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 679 Power Seat Switch: Diagrams Seat Control Switch, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 680 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 681 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 682 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left Power Seat Switch: Testing and Inspection Seat Control Switch, 10-Way - Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 685 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 686 Power Seat Switch: Testing and Inspection Seat Control Switch, 10-Way - Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 687 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 688 Power Seat Switch: Testing and Inspection Seat Control Switch, 6-Way - Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 689 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 690 Power Seat Switch: Testing and Inspection Seat Control Switch, 6-Way - Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 691 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 692 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 693 Power Seat Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 694 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 695 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 696 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 697 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 698 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 699 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 700 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 701 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 702 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 703 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 704 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 707 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 708 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 709 Power Seat Switch: Service and Repair Memory Set Switch Memory Set Switch Removal and Installation 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: For component identification and locations, refer to Seat - Exploded View, Front See: Body and Frame/Seats/Service and Repair/Front Seats/Seat - Exploded View, Front. All seats 1. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Driver seat side shield with insert 2. Release the retainers and remove the insert from the side shield. - Disconnect the electrical connectors. Driver seat side shield with cover 3. Remove the front side shield screw. 4. Remove the side shield cover. All seats 5. Release the clips and remove the memory SET switch. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 710 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Liftgate Pinch Strip, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Liftgate Pinch Strip, Left > Page 715 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch Power Trunk / Liftgate Lock Switch: Locations Handle Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 720 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 721 Power Trunk / Liftgate Lock Switch: Locations Liftgate Glass Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 722 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch Power Trunk / Liftgate Lock Switch: Diagrams Handle Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 725 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 726 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 727 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch Expedition Navigator Removal and Installation All vehicles 1. Remove the liftgate trim panel. - Position the water shield aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 728 Expedition 2. Remove the 2 nuts and the liftgate release handle. - Disconnect the electrical connector. - To install, tighten to 6 Nm (53 lb-in). 3. Remove the liftgate release switch. - Disconnect the electrical connector. Navigator 4. Remove the liftgate parking lamps. 5. Remove the 6 nuts and the license plate housing. - Disconnect the electrical connector. - To install, tighten to 5 Nm (44 lb-in). 6. Remove the 2 nuts and the liftgate release switch housing. - Disconnect the electrical connector. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the liftgate release switch. - Disconnect the electrical connector. All vehicles 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear Seat Heater Switch: Locations Heated Seat Switch, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 733 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 734 Seat Heater Switch: Locations Heated Seat Switch, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 735 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Left Rear > Page 738 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 741 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 742 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 743 Seat Heater Switch: Service and Repair Seat Control Switch - Front Seat Control Switch - Front Removal and Installation 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: For component identification and locations, refer to Seat - Exploded View, Front See: Body and Frame/Seats/Service and Repair/Front Seats/Seat - Exploded View, Front. NOTE: Driver seat shown, passenger similar. All seats 1. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Side shield with insert 2. Release the retainers and remove the insert from the side shield. - Disconnect the electrical connector(s). Side shield with cover 3. Remove the front side shield screw. 4. Remove the side shield cover. - Disconnect the electrical connector(s). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 744 All seats 5. Pull and remove the seat control switch button(s). - If equipped, remove the power recliner switch button. 6. Release the clips and remove the seat control switch. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 745 Seat Heater Switch: Service and Repair Heated Seat Switch - Second Row Heated Seat Switch - Second Row Removal and Installation 1. Release the 4 retainer clips and remove the rear cup holder. - Remove any remaining retainers from the floor console and reinstall to the cup holder before installation. 2. Remove the front floor console rear panel. - Remove the 2 screws. - Release the 6 retainer clips and separate the rear panel. - Disconnect all the electrical connectors and remove the rear panel. - Remove any remaining retainers from the floor console and reinstall to the rear cover before installation. 3. Release and remove the heated seat switch(es). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 746 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row Seat Control Switch - Third Row Removal and Installation 1. Release and remove the tray from the RH rear quarter trim panel. 2. NOTE: The LH and RH switch wiring harness electrical connectors are not interchangeable. Remove the affected seat control switch. - Release the 2 retaining tabs and detach the seat control switch from the RH rear quarter trim panel. - Pull the seat control switch through the opening and disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 750 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection Sunroof / Moonroof Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 754 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch Trunk / Liftgate Switch: Locations Liftgate Rear Control Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 759 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 760 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 761 Trunk / Liftgate Switch: Locations Power Liftgate/Traction Control/Hazard Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 762 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch > Page 765 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Position Sensor > Component Information > Service and Repair Trunk / Liftgate Position Sensor: Service and Repair Pinch Strip Switch Removal and Installation NOTE: Left side shown, right side similar. 1. Remove the brake light. - Remove the screws. 2. Disconnect the pinch strip electrical connector. 3. Remove the pinch strip. 1. Remove the pin-type retainers. 2. Remove the grommet and route the harness out of the vehicle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Position Sensor > Component Information > Service and Repair > Page 769 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations ABS Sensor Block: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 774 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 775 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Vehicles with floor shift 1. Remove the front floor console. 2. Remove the 4 bolts and the front floor console support bracket. - To install: Tighten the upper bolts to 9 Nm (80 lb-in). - Tighten the lower bolts to 40 Nm (30 lb-ft). Vehicles with column shift 3. Remove the stability control sensor cover. All vehicles 4. Disconnect the stability control sensor cluster electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 779 5. Remove the 2 bolts and the stability control sensor cluster. - To install, tighten to 12 Nm (106 lb-in). 6. To install, reverse the removal procedure. - Connect the scan tool and carry out the IVD Initialization sequence. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 783 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 784 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 788 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 789 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 793 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 794 Ford Expedition 2wd Workshop Manual (V8-5.4L (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. Disconnect the steering wheel rotation sensor electrical connector. 2. Remove the 2 bolts and the steering wheel rotation sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. 4. NOTE: If the sensor is not calibrated after installation, a DTC will be set in the ABS module. Calibrate the sensor in the following sequence: 1. Start the engine. 2. Rotate the steering wheel from lock to lock a minimum of 2 times. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 801 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 802 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 807 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 808 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (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 809 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 810 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 811 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 812 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 813 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 816 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 817 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 818 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 wheel and tire. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt and detach the retainers. - To install, tighten to 12 Nm (106 lb-in). 4. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the 2 caliper anchor bolts and position the caliper, pads and anchor plate aside. - Support the caliper with mechanic's wire. - To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the front wheel speed sensor bolt and the sensor. - To install, tighten to 18 Nm (159 lb-in). 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 821 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. Remove the parking brake shoes. 2. Disconnect the wheel speed sensor harness from the retaining clips. 3. Remove the rear wheel speed sensor bolt and the sensor. - To install, tighten to 18 Nm (159 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 833 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 834 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 835 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor and discard. - To install, tighten to 10 Nm (89 lb-in). - Coat the new CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 840 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 841 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 844 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition Navigator Removal and Installation Expedition 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 851 - Disconnect the electrical connector. Navigator 2. Remove the driver air bag module. For additional information, refer to Air Bag Systems. 3. Remove the 2 screws and the steering wheel controls bezel. 4. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 856 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 857 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 3. Remove the EOP switch. - To install, tighten to 18 Nm (159 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 865 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 866 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 870 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 871 Blower Motor Switch: Service and Repair Blower Motor Speed Control Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 875 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 876 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the upper radiator sight shield. 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 879 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor In-Vehicle Temperature Sensor - Expedition 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 883 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 884 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Air Conditioning Evaporator Temperature Sensor The evaporator temperature sensor communicates the evaporator fin temperature to the HVAC module. The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the A/C compressor clutch when the evaporator temperature sensor reading falls below acceptable levels, and by engaging the A/C compressor clutch when the discharge air temperature rises above acceptable levels. The evaporator temperature sensor electrical connector is located outside of the heater core and evaporator core housing behind the glove compartment, with the sensor pigtail leading into the housing to the sensor probe which is inserted between the evaporator core fins. The evaporator temperature sensor is not available as a separate component. To install a new evaporator temperature sensor, a new heater core and evaporator core housing must be installed. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning > Page 887 Evaporator Temperature Sensor / Switch: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 888 Evaporator Temperature Sensor / Switch: Service and Repair Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor Removal and Installation 1. Detach the glove compartment dampener and lower the glove compartment. 2. Disconnect the evaporator discharge air temperature sensor electrical connector. 3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 894 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 Expedition 2wd Workshop Manual (V8-5.4L (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 895 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 899 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 900 Solar Sensor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Navigator shown, Expedition similar. Removal and Installation 1. Remove the Instrument Cluster (IC) finish panel. 2. Press the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 909 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 910 Door Switch: Locations Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 911 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 912 Door Switch: Locations Door Ajar Switch, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 913 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 916 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 917 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 918 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 919 Door Switch: Service and Repair Door Ajar Switch NOTE: LH front door latch shown, others similar. Removal and Installation 1. Remove the 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 or Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: Customer Interest Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 928 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 934 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module Fuel Gauge Sender: Locations Fuel Pump Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 937 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 938 Fuel Gauge Sender: Locations Fuel Pump (FP) Control Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 939 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 940 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 943 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 946 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 947 Fuel Gauge Sender: Service and Repair Fuel Pump Module Fuel Pump Module 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 948 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. All fuel tanks 1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank. 127L (33.5 gal) fuel tank 2. Remove the 4 nuts and the Fuel Pump (FP) module cover. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the return fuel tube-to-FP module quick connect coupling. All fuel tanks 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. 5. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring. 106L (28 gal) fuel tank 6. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 949 Remove the FP and FP O-ring seal. If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange. - Discard the FP O-ring seal. 127L (33.5 gal) fuel tank 7. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: Note the location of the FP alignment tabs. Remove the FP module assembly. Remove and discard the O-ring seal. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 953 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 954 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair Light Sensor NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Using a suitable tool (such as a pocket screwdriver), remove the light sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment Technical Service Bulletin # 09C09 Date: 090817 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on June 17, 2009. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment > Page 967 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment > Page 968 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment > Page 969 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment > Page 970 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > NHTSA09V232000 > Jun > 09 > Recall 09V232000: Brake Light Switch Adjustment Brake Light Switch: Recalls Recall 09V232000: Brake Light Switch Adjustment VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Expedition 2009 Lincoln/Navigator 2009 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: June 23, 2009 NHTSA CAMPAIGN ID NUMBER: 09V232000 NHTSA ACTION NUMBER: N/A COMPONENT: Service Brakes, Hydraulic: Switches: Brake Light POTENTIAL NUMBER OF UNITS AFFECTED: 1357 SUMMARY: Ford is recalling 1,357 M/Y 2009 Expedition and Navigator vehicles for failing to comply with the Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment." The brake stop lamp switch may be improperly adjusted. This may result in a delay in brake stoplamp illumination when the brake pedal is depressed. In situations of very mild brake application, the brake stoplamps may not illuminate. CONSEQUENCE: Delay or loss of brake stoplamp function may increase the risk of a crash. REMEDY: Dealers will adjust the brake stoplamp switch free of charge. The recall is expected to begin on or before July 6, 2009. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332 or www.ownerconnection.com. NOTES: Ford recall No. 09C09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance Technical Service Bulletin # 09C09 Date: 090617 Attachment I - Administrative Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 979 OASIS ACTIVATED? Yes, OASIS will be activated on June 17,2009. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 980 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 981 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 982 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment Technical Service Bulletin # 09C09 Date: 090817 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on June 17, 2009. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 988 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 989 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 990 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 991 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > NHTSA09V232000 > Jun > 09 > Recall 09V232000: Brake Light Switch Adjustment Brake Light Switch: All Technical Service Bulletins Recall 09V232000: Brake Light Switch Adjustment VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Expedition 2009 Lincoln/Navigator 2009 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: June 23, 2009 NHTSA CAMPAIGN ID NUMBER: 09V232000 NHTSA ACTION NUMBER: N/A COMPONENT: Service Brakes, Hydraulic: Switches: Brake Light POTENTIAL NUMBER OF UNITS AFFECTED: 1357 SUMMARY: Ford is recalling 1,357 M/Y 2009 Expedition and Navigator vehicles for failing to comply with the Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment." The brake stop lamp switch may be improperly adjusted. This may result in a delay in brake stoplamp illumination when the brake pedal is depressed. In situations of very mild brake application, the brake stoplamps may not illuminate. CONSEQUENCE: Delay or loss of brake stoplamp function may increase the risk of a crash. REMEDY: Dealers will adjust the brake stoplamp switch free of charge. The recall is expected to begin on or before July 6, 2009. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332 or www.ownerconnection.com. NOTES: Ford recall No. 09C09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance Technical Service Bulletin # 09C09 Date: 090617 Attachment I - Administrative Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 1000 OASIS ACTIVATED? Yes, OASIS will be activated on June 17,2009. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 1001 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 1002 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 1003 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1004 Brake Light Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1005 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1006 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1007 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 1008 Brake Light Switch: Service and Repair Stoplamp Switch Removal 1. Disconnect the stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 N [1-3 lb]), pull rearward on the brake pedal, rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. Installation NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the stoplamp switch. Failure to follow these instructions may damage the stoplamp switch. 1. Without movement to the brake pedal assembly, install the stoplamp switch and rotate 45 degrees counterclockwise. 2. Connect the stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1013 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1014 Door Switch: Locations Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1015 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1016 Door Switch: Locations Door Ajar Switch, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1017 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 1020 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 1021 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 1022 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 1023 Door Switch: Service and Repair Door Ajar Switch NOTE: LH front door latch shown, others similar. Removal and Installation 1. Remove the 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 or Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1027 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1028 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1029 Hazard Warning Switch: Service and Repair Hazard Flasher Lamp Switch NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Remove the instrument panel center finish panel. 2. Release the tabs and remove the hazard flasher lamp switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 1033 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 1036 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1039 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1040 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1041 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 1042 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1046 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1047 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1048 Headlamp Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1049 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1050 Headlamp Switch: Service and Repair Headlamp Switch Expedition Navigator Removal and Installation Expedition Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1051 1. Remove the screw and the LH lower instrument panel finish panel. - Disconnect the electrical connector. Navigator 2. Remove the 3 screws and the steering column finish panel. - Disconnect the electrical connectors. All vehicles 3. NOTE: The headlamp switch is removed by releasing the tabs and pushing from behind. Remove the headlamp switch. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1055 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1056 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1060 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1061 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1062 Turn Signal Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1063 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1064 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Accelerator Pedal Position Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1070 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1071 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1072 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1076 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1077 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls Air Flow Meter/Sensor: Description and Operation Electronic Engine Controls Electronic Engine Controls Mass Air Flow (MAF) Sensor The MAF sensor: - sends the PCM a signal indicating mass airflow rate of air entering the engine. - incorporates the Intake Air Temperature (IAT) sensor. For removal and installation, refer to Mass Air Flow (MAF) Sensor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls > Page 1080 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls > Page 1081 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Page 1082 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 > Page 1087 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1090 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1091 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1092 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation LH Camshaft Position (CMP) sensor 1. Remove the Air Cleaner (ACL) outlet pipe. All CMP sensors 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1102 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1103 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1104 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt from the A/C compressor pulley. 3. Disconnect the A/C compressor electrical connector. 4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1105 7. To install, reverse the removal procedure. 8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1109 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1110 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1111 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor and discard. - To install, tighten to 10 Nm (89 lb-in). - Coat the new CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1117 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1118 Fuel Level Sensor: Service and Repair Fuel Pump Module Fuel Pump Module 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1119 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. All fuel tanks 1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank. 127L (33.5 gal) fuel tank 2. Remove the 4 nuts and the Fuel Pump (FP) module cover. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the return fuel tube-to-FP module quick connect coupling. All fuel tanks 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. 5. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring. 106L (28 gal) fuel tank 6. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1120 Remove the FP and FP O-ring seal. If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange. - Discard the FP O-ring seal. 127L (33.5 gal) fuel tank 7. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: Note the location of the FP alignment tabs. Remove the FP module assembly. Remove and discard the O-ring seal. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1124 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1125 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1126 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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Service and Repair > Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor 106L (28 Gal) Fuel Tank 125L (33 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Service and Repair > Fuel Tank Pressure Sensor > Page 1129 Removal and Installation All fuel tanks 1. Remove the fuel tank. 106L (28 gal) fuel tank 2. Disconnect the fuel supply tube-to-heat shield pushpin retainer. 125L (33 gal) fuel tank 3. Remove the fuel tank heat shield retainer(s). All fuel tanks 4. Remove the fuel tank heat shield. 5. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-fuel vapor/grade vent valves quick connect couplings. 6. Disconnect the FTP sensor and vapor tube assembly-to-fuel pump module quick connect coupling. 7. Remove the FTP sensor and vapor tube assembly from the fuel tank. 8. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Service and Repair > Fuel Tank Pressure Sensor > Page 1130 Fuel Tank Pressure Sensor: Service and Repair Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Service and Repair > Fuel Tank Pressure Sensor > Page 1131 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1135 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1136 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1137 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1 > Page 1142 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 1145 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1146 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1147 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1158 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1159 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1160 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1161 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1162 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1165 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1166 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1167 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1170 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1173 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. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. - Apply penetrating lubricant to the HO2S to assist in removal. Installation 1. Install the HO2S. - Apply a light coat of high temperature nickel anti-seize lubricant to the HO2S threads prior to installation. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft). 2. Connect the HO2S electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1174 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 3. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. - Apply penetrating lubricant to the CMS to assist in removal. Installation 1. Install the CMS. - Apply a light coat of high temperature nickel anti-seize lubricant to the CMS threads prior to installation. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft). 2. Connect the CMS electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Power Steering Pressure Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1178 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1179 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1182 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1189 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1192 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1193 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal 1. Remove the Throttle Body (TB). 2. 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 ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 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 1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB. 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). 2. Install the TB. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1198 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Accelerator Pedal Position Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1207 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1208 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1209 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1213 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1214 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls Air Flow Meter/Sensor: Description and Operation Electronic Engine Controls Electronic Engine Controls Mass Air Flow (MAF) Sensor The MAF sensor: - sends the PCM a signal indicating mass airflow rate of air entering the engine. - incorporates the Intake Air Temperature (IAT) sensor. For removal and installation, refer to Mass Air Flow (MAF) Sensor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls > Page 1217 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls > Page 1218 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Page 1219 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Inertia Fuel Shutoff Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1229 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1230 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1231 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1232 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1233 Inertia Fuel Shutoff Switch: Service and Repair Inertia Fuel Shutoff (IFS) Switch Removal and Installation 1. NOTE: The Inertia Fuel Shutoff (IFS) switch is located behind the LH quarter trim panel access cover. Remove the LH quarter trim panel access cover. 2. Remove the power liftgate motor electrical connector pushpins from the power liftgate motor bracket. 3. NOTE: Slide the IFS switch out below the power liftgate motor bracket. Remove the 2 bolts and the IFS switch. To install, tighten to 2 Nm (18 lb-in). 4. Disconnect the IFS switch electrical connector. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1237 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1240 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1241 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal 1. Remove the Throttle Body (TB). 2. 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 ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 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 1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB. 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). 2. Install the TB. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 > Page 1247 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1250 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1251 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1252 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation LH Camshaft Position (CMP) sensor 1. Remove the Air Cleaner (ACL) outlet pipe. All CMP sensors 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1256 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1257 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1258 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt from the A/C compressor pulley. 3. Disconnect the A/C compressor electrical connector. 4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1259 7. To install, reverse the removal procedure. 8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. If a new lock cylinder with keys is replaced, the new PATS keys must be programmed. 4. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1265 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 1270 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 1273 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1274 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1275 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor Impact Sensor: Locations Front Impact Severity Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1281 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1282 Impact Sensor: Locations Driver Side Impact Sensor, C-Pillar Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1283 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1284 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1285 Impact Sensor: Locations Passenger Side Impact Sensor, C-Pillar Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1286 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1287 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1288 Impact Sensor: Locations Driver Front Door, Side Impact Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1289 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1290 Impact Sensor: Locations Passenger Front Door, Side Impact Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 1291 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 1294 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 1295 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 1296 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 1297 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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. NOTE: The front impact severity sensor is located on the bottom of the lower radiator support. 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 portion. 2. Disconnect the front impact severity sensor electrical connector. 3. 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 11 Nm (97 lb-in). 4. To install, reverse the removal procedure. 5. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1300 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar Side Impact Sensor - C-Pillar NOTE: Expedition/Navigator shown, Expedition EL/Navigator L similar. NOTE: RH side shown, LH side 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 Supplemental Restraint System (SRS) fuse is removed and the ignition is ON. NOTE: The 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 portion. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. Remove the bolt and second row safety belt retractor anchor. - To install, tighten to 40 Nm (30 lb-ft). 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar and release the retaining clips to gain access to the C-pillar side impact sensor. 6. Disconnect the side impact sensor electrical connector. 7. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1301 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 C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the bolt and side impact sensor. To install, tighten to 11 Nm (97 lb-in). 8. 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. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1302 Impact Sensor: Service and Repair Side Impact Sensor - Front Door Side Impact Sensor - Front Door NOTE: RH door shown, LH 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 portion. 2. Remove the front door trim panel. 3. Separate the weathershield from the door enough to access the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. Remove the 2 bolts and side impact sensor. 6. NOTICE: To prevent stripping the insert nuts, tighten the side impact sensor bolts only enough to retain the side impact sensor correctly. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1303 - Inspect the insert nut for damage. If the insert nut is damaged, install a new insert. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1307 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 similar. 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. Move the driver seat to the full forward and highest position. 2. Change to Ignition Off. Wait 1 minute. 3. Remove the seat position sensor and bracket bolt. 4. Unhook the seat position sensor and bracket from the seat track cross brace. 5. Disconnect the electrical connector and remove the seat position sensor and bracket. 6. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1314 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. If a new lock cylinder with keys is replaced, the new PATS keys must be programmed. 4. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1321 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1327 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1328 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1331 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1335 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1336 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Locations > Page 1340 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Locations > Page 1344 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair Ride Height Sensor: Service and Repair Suspension Height Sensor LH Side RH Side Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Page 1349 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the height sensor harness from the sensor bracket. 3. Disconnect the height sensor electrical connector. 4. Disconnect the height sensor arm from the ball stud on the lower control arm. 5. Remove and discard the 2 height sensor bolts. - To install, tighten to 11 Nm (97 lb-in). 6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the LH and RH height sensors. For additional information, refer to Ride Height Adjustments See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic )/Service and Repair/Ride Height Adjustments. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1353 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1354 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1360 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1361 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1364 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1365 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1366 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1367 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 1376 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 1377 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 Expedition 2wd Workshop Manual (V8-5.4L (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 (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The Tow/Haul switch is not replaceable. If a new Tow/Haul switch is required, install a new selector lever assembly. 1. For additional information, refer to Selector Lever - Column Shift See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever - Column Shift. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 (TC) Switch - Column Shift > Page 1380 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal and Installation NOTE: The Tow/Haul switch is not serviced. If a new switch is required, install a new selector lever knob assembly. 1. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch Power Window Switch: Locations Master Window Adjust Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1386 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1387 Power Window Switch: Locations Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1388 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1389 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1390 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1393 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1394 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1395 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1396 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1397 Power Window Switch: Diagrams Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1398 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1401 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1402 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1403 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1404 Power Window Switch: Testing and Inspection Window Adjust Switches - Left Rear and Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1405 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1406 Power Window Switch: Service and Repair Window Control Switch Removal and Installation NOTE: LF shown, all others similar. 1. Remove the door trim panel. 2. NOTE: There are 2 tabs on the opposite side not shown in the illustration. Unlock the 4 tabs and remove the window control switch from the door trim panel. 3. To install, reverse removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 09-24-13 > Dec > 09 > Wipers/Washers - Rain Sensor Detached From Windshield Rain Sensor: Customer Interest Wipers/Washers - Rain Sensor Detached From Windshield TSB 09-24-13 12/14/09 RAIN SENSOR MOUNTING RING DETACHED FROM WINDSHIELD FORD: 2010 Taurus 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 MKS 2010 MKZ 2009-2010 Navigator 2010 MKT ISSUE Some 2009-2010 F-150 Platinum, Expedition, Navigator, MKS and 2010 Taurus, MKT and MKZ vehicles equipped with Rain Sensing Windshield Wipers may exhibit a detached rain sensor mounting ring. The rain sensor mounting ring is attached to the inside of the windshield near the rear view mirror. The windshield wipers will continue to function in manual mode, only the rain sensor feature is affected. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A service repair kit has been made available to resolve this issue. Order the Rain Sensor Repair Kit and follow the instruction sheet contained with this kit to resolve a detached rain sensor mounting ring. NOTE THE KIT REQUIRES CHEMICALS WHICH ARE NOT INCLUDED IN THE KIT. THESE CHEMICALS HAVE A SHORT SHELF LIFE AND ARE REQUIRED TO BE OBTAINED DIRECTLY FROM A SOURCE LISTED IN THE INSTRUCTION SHEET. 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 MT092413 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 17D596 33 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-24-13 > Dec > 09 > Wipers/Washers - Rain Sensor Detached From Windshield Rain Sensor: All Technical Service Bulletins Wipers/Washers - Rain Sensor Detached From Windshield TSB 09-24-13 12/14/09 RAIN SENSOR MOUNTING RING DETACHED FROM WINDSHIELD FORD: 2010 Taurus 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 MKS 2010 MKZ 2009-2010 Navigator 2010 MKT ISSUE Some 2009-2010 F-150 Platinum, Expedition, Navigator, MKS and 2010 Taurus, MKT and MKZ vehicles equipped with Rain Sensing Windshield Wipers may exhibit a detached rain sensor mounting ring. The rain sensor mounting ring is attached to the inside of the windshield near the rear view mirror. The windshield wipers will continue to function in manual mode, only the rain sensor feature is affected. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A service repair kit has been made available to resolve this issue. Order the Rain Sensor Repair Kit and follow the instruction sheet contained with this kit to resolve a detached rain sensor mounting ring. NOTE THE KIT REQUIRES CHEMICALS WHICH ARE NOT INCLUDED IN THE KIT. THESE CHEMICALS HAVE A SHORT SHELF LIFE AND ARE REQUIRED TO BE OBTAINED DIRECTLY FROM A SOURCE LISTED IN THE INSTRUCTION SHEET. 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 MT092413 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 17D596 33 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rain Sensor: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 Valve Body: All Technical Service Bulletins A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. 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 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rain Sensor: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 > Page 1426 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rain Sensor: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 > Page 1432 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 1433 Rain Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 1434 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 1435 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 1436 Rain Sensor: Service and Repair Rain Sensor Removal and Installation 1. Pull outward on the rain sensor cover to remove. 2. Disconnect the rain sensor electrical connector. 3. NOTE: Prior to releasing the rain sensor retaining clips, it is necessary to apply light inward pressure at the bend of the retaining clips. Using a suitable screwdriver, release the 2 rain sensor retaining clips from the windshield mounted bracket and remove the rain sensor. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1440 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1441 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1445 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1446 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1447 Windshield Washer Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1448 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1449 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1450 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1454 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1455 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1456 Wiper Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1457 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1458 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1459 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Alignment Specifications Vehicles With Rear Coil Spring Suspension Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1465 Alignment Specifications Vehicles With Rear Air Suspension Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1466 Alignment: Specifications Ball Joint Deflection, Ride Height, and Vehicle Lean Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1467 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1468 Alignment: Specifications Torque Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 affect on tire wear. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1471 Alignment: Description and Operation Caster Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 does not affect tire wear. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1472 Alignment: Description and Operation Drift/Pull Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1473 Alignment: Description and Operation Nibble Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces or tire imbalance. This condition is observed by the driver as small rotational oscillations of the steering wheel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1474 Alignment: Description and Operation Camber Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 affect on tire wear. Caster Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 does not affect tire wear. Drift/Pull Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1475 - 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 Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces or tire imbalance. This condition is observed by the driver as small rotational oscillations of the steering wheel. Poor Groove Feel Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." - Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. - In the diagnosis of a steering or alignment concern, it is important to understand the difference between wander and poor groove feel. Poor Returnability/Sticky Steering Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 when the steering correction is completed. Shimmy Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 Wheel Alignment Angles Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1476 The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Toe Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: - affects tire wear and directional stability. - must be checked after adding aftermarket equipment, such as a snowplow. Wander Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement 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's arm until the scriber point is located in the center of the lower arm rearward 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's arm until the scriber point is located on the lower surface of the wheel knuckle near the ball joint. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 1479 5. Subtract measurement 3 from measurement 2 to obtain the front ride height. - For additional information, 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 rearward bolt (measurement 2). 2. Measure the distance between the flat level surface and the center of the shock absorber lower bolt (rearward side) (measurement 3). 3. Subtract measurement 3 from measurement 2 to obtain the rear ride height. - For additional information, refer to Specifications. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 1480 Alignment: Service and Repair Camber And Caster Adjustment - Front Camber and Caster Adjustment - Front NOTICE: Do not remove the stabilizer bar brackets until the stabilizer links have been disconnected or damage to the stabilizer bar links may occur. NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. NOTE: To allow for adjustment of the lower arm in the frame slots, the lower arm bolts and nuts must be removed and discarded. They are replaced with cam bolt kit 3C333. The vehicle should be supported by the frame to ease movement of the lower arm in the slot. 1. Using alignment equipment and the manufacturers instructions, measure the front caster and camber. - Refer to Alignment Specifications in the Specifications portion for optimal alignment settings. - If the caster and camber values are not within specification, go to the next step. 2. Remove and discard the lower arm front and rear nuts and bolts. 3. NOTICE: Do not hold the stabilizer link boot with any tool, as damage to the boot will occur. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nuts. Remove and discard the stabilizer bar link lower nuts. 4. Remove the 4 stabilizer bar bracket nuts, 2 stabilizer bar brackets and position the stabilizer bar aside. 5. Remove the stabilizer bar bracket bolts and plate assembly. 6. Install the front cam bolt kit and loosely install the nut. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 1481 7. Install the rear cam bolt kit and loosely install the nut. 8. To adjust the caster and camber, refer to the following chart. - Adjustments that require moving the front and the rear of the lower arm should be made equally. 9. With the weight of the vehicle resting on the wheel and tire assemblies, hold the front cam bolt and tighten the nut to 350 Nm (258 lb-ft). 10. With the weight of the vehicle resting on the wheel and tire assemblies, hold the rear cam bolt and tighten the nut to 350 Nm (258 lb-ft). 11. Install the 2 stabilizer bar bracket bolts and plate assembly. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 1482 12. Position the stabilizer bar, install the 2 stabilizer bar brackets and the 4 stabilizer bar bracket nuts. - Tighten the nuts to 55 Nm (41 lb-ft). 13. NOTICE: Do not hold the stabilizer link boot with any tool, as damage to the boot will occur. NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nuts. Install the 2 stabilizer bar link lower nuts. - Tighten the nuts to 80 Nm (59 lb-ft). 14. Check and, if necessary, adjust the front toe. For additional information, refer to Toe Adjustment - Front See: Toe Adjustment - Front. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 1483 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. 1. Using alignment equipment and the manufacturer's instructions, measure the front toe. - Refer to Alignment Specifications in the Specifications portion for optimal alignment settings. - If the front toe values are not within specification, go to the next step. 2. Start the engine and center the steering wheel. 3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the straight-ahead position. 4. Remove the steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). 6. NOTE: Do not allow the steering gear bellows to twist while rotating the tie rod. Rotate the tie rod(s) to achieve the desired toe setting. 7. NOTICE: Make sure to hold the tie-rod end stationary while tightening the jam nut or damage to the boot may occur. NOTE: Make sure that the toe settings are not disturbed while tightening the jam nuts. Tighten the tie-rod end jam nut(s) to 103 Nm (76 lb-ft). 8. Install the steering gear bellows clamp(s). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 1484 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 1485 Alignment: Service and Repair Toe Adjustment - Rear Toe Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear toe. NOTE: Before carrying out a toe adjustment, check the tires for the correct pressure. Inspect the tires for incorrect wear or damage. Inspect the suspension for wear or damage. 1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. - Refer to Alignment Specifications in the Specifications portion for optimal alignment settings. - If the rear toe values are not within specification, go to the next step. 2. Loosen the toe link cam bolt nut(s). 3. Rotate the toe link cam bolt(s) until the toe setting is within specification. 4. NOTE: Make sure the toe settings are not disturbed while tightening the cam nut(s). Tighten the toe link cam bolt nut(s) to 275 Nm (203 lb-ft). 5. Recheck the rear toe setting, adjust as necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 1486 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear camber or toe. NOTE: Before carrying out a camber adjustment, check the tires for the correct pressure. Inspect the tires for incorrect wear or damage. Inspect the suspension for wear or damage. 1. Using alignment equipment and the manufacturer's instructions, measure the rear camber. - Refer to Alignment Specifications in the Specifications portion for optimal alignment settings. - If the rear camber value is not within specification, go to the next step. 2. Remove the upper arm-to-frame bolt and the camber set shim. - Discard the camber set shim. - Install and snug the upper arm-to frame bolt. 3. Position the upper arm-to-frame bolt in the upper arm-to-frame slot until the camber setting is within specification. 4. NOTE: Do not allow the upper arm to move and change the camber adjustment setting when tightening the bolt. Tighten the upper arm-to-frame bolt to 225 Nm (166 lb-ft). 5. Recheck the camber setting, adjust as necessary. 6. Check and, if necessary, adjust the rear toe. For additional information, refer to Toe Adjustment Rear See: Toe Adjustment - Rear. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Engine running..................................................................................................................................... ..............................................379-414 kPa (55-60 psi) Key ON Engine OFF (KOEO)......................... ..................................................................................................................................379-414 kPa (55-60 psi) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1491 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. Remove the cap from the fuel pressure relief valve located on the fuel rail. 2. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 3. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 4. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place 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. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1492 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 695 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1501 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element Removal and Installation 1. Disconnect the Air Cleaner (ACL) outlet pipe from the ACL cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Release the retaining clips and position the ACL cover aside. 4. Remove the ACL element. 5. NOTE: The ACL element must be fully seated into the ACL housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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: 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. 1. Disconnect the battery ground cable. 2. Remove the cap from the fuel pressure relief valve located on the fuel rail. 3. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 4. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the Fuel Pressure Test Kit and relieve the fuel pressure. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1506 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order Firing Order: Specifications Firing Order Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order > Page 1511 Firing Order: Specifications Engine Cylinder Identification Engine Cylinder Identification Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Base ignition timing.............................................................................................................................. ........................10° Before Top Dead Center (BTDC) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... .................................1.05 ± 0.05 mm (0.039-0.043 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1519 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................12 Nm (106 lb-in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1520 Spark Plug: Application and ID Spark plug............................................................................................................................................ ...................................................................HJFS-24FP Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1521 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1522 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Engine Ignition - RH Engine Ignition - LH 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 1525 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal NOTICE: The spark plug procedure must be followed exactly or damage to the cylinder head and spark plug will result. 1. Remove the ignition coil-on-plug. For additional information, refer to Ignition Coil-On-Plug See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plug. 3. Inspect the spark plug. Installation 1. Adjust the spark plug gap as necessary. For the correct spark plug gap specification, refer to Specifications. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Install the spark plug. - To install, tighten to 12 Nm (106 lb-in). 3. Install the ignition coil. For additional information, refer to Ignition Coil-On-Plug See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1529 Compression Check: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1530 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Accessory Drive Accessory Drive Belt Routing Front End Accessory Drive (FEAD) Components Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Component Tests 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Noise/Flutter > Page 1536 Drive Belt: Testing and Inspection Drive Belt - Incorrect Installation Accessory Drive Component Tests 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1539 Drive Belt: Service and Repair Accessory Drive Belt Accessory Drive Belt Removal and Installation 1. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 2. NOTE: Make sure the drive belt is correctly installed on each pulley. To install, reverse the removal procedure. - Refer to Accessory Drive See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Description and Operation in Description and Operation for drive belt routing. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 1546 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element Removal and Installation 1. Disconnect the Air Cleaner (ACL) outlet pipe from the ACL cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Release the retaining clips and position the ACL cover aside. 4. Remove the ACL element. 5. NOTE: The ACL element must be fully seated into the ACL housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View Evaporative Canister Filter: Service and Repair Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View > Page 1554 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1558 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1559 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/Transmission Fluid Drain And Refill. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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: 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. 1. Disconnect the battery ground cable. 2. Remove the cap from the fuel pressure relief valve located on the fuel rail. 3. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 4. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the Fuel Pressure Test Kit and relieve the fuel pressure. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1564 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Coolant Crossover Manifold Assembly Removal and Installation 1. The coolant crossover manifold assembly is serviced with the intake manifold. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line Auxiliary Evaporator Outlet and Inlet Line Removal Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1573 NOTE: The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly for Expedition or Navigator vehicles. The auxiliary evaporator inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. NOTE: The auxiliary evaporator inlet and outlet lines for Expedition EL or Navigator L vehicles are installed from the factory as a single one-piece assembly including both lines. The replacement part is supplied as a multiple-piece kit for ease of installation. NOTE: For Expedition or Navigator vehicles, the following procedure can be used to remove and install one or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. For Expedition EL or Navigator L vehicles, both lines must be removed. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. NOTE: If only one auxiliary evaporator line is to be removed, disconnect only the desired line. Remove the auxiliary evaporator outlet and inlet line front fitting nut(s) and disconnect the fitting(s). - Discard the O-ring seals and gasket seals. 4. Remove the spare tire. 5. Remove the RH front wheel and tire. 6. Remove the RH fender splash shield. 7. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. 8. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition or Navigator only 9. NOTE: Both A/C fittings must be disconnected even if only one line is to be removed. Disconnect the auxiliary evaporator outlet and inlet line rear fittings. - Discard the O-ring seals. Expedition EL or Navigator L only 10. Remove the RH rear wheel and tire assembly. 11. Remove the auxiliary evaporator outlet and inlet line rear fitting nut and disconnect the fitting. - Discard the gasket seals. All vehicles 12. Remove the muffler. 13. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 14. Remove the 3 muffler heat shield bolts and the heat shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1574 15. Remove the 2 exhaust hanger bolts and the exhaust hanger. 16. Remove the RH Catalyst Monitor Sensor (CMS). 17. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 18. Remove the 3 remaining auxiliary line bracket nuts and the auxiliary line brackets. 19. NOTE: If installing only one auxiliary evaporator line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary evaporator line(s) in the same position as the fittings on the new line(s). Expedition EL or Navigator L only 20. Remove the center section(s) of the auxiliary evaporator line(s) through the RH rear wheel well opening between the body and the frame. Expedition or Navigator only 21. Remove the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the front of the vehicle between the RH catalytic converter and frame. All vehicles 22. Remove the remaining auxiliary evaporator inlet and outlet line pieces. Installation Expedition or Navigator only 1. Install the rear portion of the auxiliary evaporator line(s) and connect the auxiliary evaporator outlet and inlet line rear fittings. - Install new O-ring seals. Expedition EL or Navigator L only 2. Install the rear portion of the auxiliary evaporator outlet and inlet line. 3. Connect the auxiliary evaporator outlet and inlet line rear fitting and install the nut. - Install new gasket seals. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1575 - Tighten to 12 Nm (106 lb-in). All vehicles 4. Install the front portion of the auxiliary evaporator outlet and inlet line(s). 5. Connect the evaporator outlet and inlet line front fitting(s) and install the nut(s). - Install new O-ring seals and gasket seals. - Tighten to 15 Nm (133 lb-in). Expedition EL or Navigator L only 6. NOTE: Loosely connect, but do not tighten, the fittings. Install the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the front of the vehicle through RH rear wheel well opening between the body and the frame. Expedition or Navigator only 7. NOTE: Loosely connect, but do not tighten, the fittings. Install the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the rear of the vehicle through the opening between the RH catalytic converter and frame. All vehicles 8. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). 9. NOTE: Expedition/Navigator shown, Expedition EL or Navigator L similar. Tighten the middle auxiliary evaporator line fittings. 10. Inspect the auxiliary evaporator lines for correct installation. Loosen, reposition and tighten as needed. 11. Install the RH catalytic converter heat shield and the 3 rear catalytic converter heat shield bolts. 12. Install the exhaust hanger and the 2 exhaust hanger bolts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1576 13. Install the muffler heat shield and the 3 muffler heat shield bolts. 14. Install the RH CMS. 15. Install the muffler. 16. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 17. Install the front auxiliary line bracket and the front auxiliary line bracket nut. - Tighten to 5 Nm (44 lb-in). 18. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 19. Install the RH front fender splash shield. 20. Install the RH front wheel. Expedition EL or Navigator L only 21. Install the RH rear wheel and tire assembly. All vehicles 22. Install the spare tire. 23. Lubricate the refrigerant system with the correct amount of clean PAG oil. 24. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1577 Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line Compressor to Condenser Discharge Line Removal and Installation 1. Recover the refrigerant. 2. 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). 3. Remove the condenser inlet jumper line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Remove the compressor-to-condenser discharge line. 5. If removing the condenser inlet jumper line, remove the RH headlamp assembly. 6. If removing the condenser inlet jumper line, disconnect the A/C pressure transducer electrical connector. 7. If removing the condenser inlet jumper line, remove the condenser inlet fitting bolt and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1578 8. Remove the condenser inlet jumper line. 9. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1579 Hose/Line HVAC: Service and Repair Thermostatic Expansion Valve Manifold and Tube Assembly Thermostatic Expansion Valve Manifold and Tube Assembly Removal and Installation 1. Recover the refrigerant. 2. Remove the RH headlamp assembly. 3. Remove the condenser outlet 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 3 PCM electrical connectors. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1580 5. Disconnect the 2 wire harness electrical connectors at the RH inner fender splash shield. 6. Remove the Thermostatic Expansion Valve (TXV) manifold and tube assembly bracket bolt. 7. Remove the TXV manifold and tube suction fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 10. Remove the TXV fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 11. Remove the TXV manifold and tube assembly. 12. To install, reverse the removal procedure. - Install new gasket seals and 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1581 Hose/Line HVAC: Service and Repair Auxiliary Heater Outlet and Inlet Line Auxiliary Heater Outlet and Inlet Line Removal NOTE: The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. NOTE: The following procedure can be used to remove and install one or both the auxiliary heater inlet and auxiliary heater outlet lines. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1582 All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the spare tire. 4. Remove the RH front wheel and tire. 5. Remove the RH fender splash shield. 6. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and/or inlet line front quick disconnect fitting(s). 7. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. 8. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition EL or Navigator L only 9. Remove the RH rear wheel and tire assembly. All vehicles 10. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and inlet line rear quick disconnect fitting(s) from the heater core at the floor pan connection. 11. Remove the muffler. 12. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 13. Remove the 3 muffler heat shield bolts and the muffler heat shield. 14. Remove the 2 exhaust hanger bolts and the exhaust hanger. 15. Remove the RH Catalyst Monitor Sensor (CMS). 16. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 17. Remove the 3 remaining auxiliary line bracket nuts and the line brackets. 18. NOTE: If installing only one auxiliary heater line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1583 Expedition EL or Navigator L only 19. Remove the center section(s) of the auxiliary heater line(s) through the RH rear wheel well opening between the body and the frame. Expedition or Navigator only 20. Remove the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the front of the vehicle between the RH catalytic converter and frame. All vehicles 21. Remove the remaining auxiliary heater inlet and outlet line pieces. Installation All vehicles 1. Install the rear portion of the auxiliary heater outlet and inlet line(s) and connect the quick disconnect fittings. 2. Install the front auxiliary heater line(s) and connect the quick disconnect fittings. Expedition EL or Navigator L only 3. NOTE: Loosely connect, but do not tighten, the fittings. Install the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the front of the vehicle through RH rear wheel well opening between the body and the frame. Expedition or Navigator only 4. NOTE: Loosely connect, but do not tighten, the fittings. Install the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the rear of the vehicle through the opening between the RH catalytic converter and frame. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 1584 All vehicles 5. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). 6. Tighten the middle auxiliary heater line fittings. 7. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed. 8. Install the RH catalytic converter heat shield and the 3 catalytic converter heat shield rear bolts. 9. Install the RH CMS. 10. Install the exhaust hanger and the 2 exhaust hanger bolts. 11. Install the muffler heat shield and the 3 muffler heat shield bolts. 12. Install the muffler. 13. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 14. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 15. Install the front auxiliary line bracket and the front auxiliary line bracket and nut. - Tighten to 5 Nm (44 lb-in). 16. Install the RH front fender splash shield. 17. Install the RH front wheel and tire. Expedition EL or Navigator L only 18. Install the RH rear wheel and tire. All vehicles 19. Install the spare tire. 20. Fill the engine cooling system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose Power Steering Line/Hose: Service and Repair Steering Gear To Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose 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. Remove the upper air deflector. 1. Remove the 10 upper air deflector pin-type retainers. 2. Remove the air deflector. 3. Remove the air cleaner outlet pipe. 4. Release the clamp and disconnect the power steering gear-to-fluid cooler return hose from the power steering fluid cooler. 5. Release the lower cooling fan shroud tab and rotate the shroud upward. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose > Page 1589 6. Remove the 2 bolts and the oil drip shield. - To install, tighten to 7 Nm (62 lb-in). 7. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering gear-to-fluid cooler return hose. - To install, tighten to 23 Nm (17 lb-ft). 8. To install, reverse the removal procedure. 9. Fill the power steering system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose > Page 1590 Power Steering Line/Hose: Service and Repair Power Steering Pump To Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line 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. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley See: Steering and Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose > Page 1591 Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Pulley. 2. Remove the 2 bolts and the oil drip shield. - To install, tighten to 7 Nm (62 lb-in). 3. Disconnect the power steering pressure line-to-power steering pump fitting. - To install, tighten to 65 Nm (48 lb-ft). 4. Disconnect the Power Steering Pressure (PSP) switch electrical connector. 5. Remove the power steering pressure line bracket-to-crossmember bolt. - To install, tighten to 7 Nm (62 lb-in). 6. Remove the power steering pressure line bracket-to-engine nut. - To install, tighten to 40 Nm (30 lb-ft). 7. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering pressure line. - To install, tighten to 23 Nm (17 lb-ft). 8. To install, reverse the removal procedure. 9. Fill the power steering system. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 P/N .............................................................................................................................................. .................................................................. PM-1-C Ford Specification ................................................................................................................................................... WSS-M6C62-A or WSS-M6C65-A1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant BASE RADIATOR Without aux rear heat .......................................................................................................................... ........................................ 16.4 quarts (15.5 liters) With aux rear heat ................................................ ....................................................................................................................... 19.0 quarts (18.0 liters) HEAVY DUTY TRAILER TOW RADIATOR Without aux rear heat .......................................................................................................................... ........................................ 16.9 quarts (16.0 liters) With aux rear heat ................................................ ....................................................................................................................... 19.5 quarts (18.5 liters) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1600 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant (yellow-colored) Ford P/N .............................................................................................................................................. .................................................................. VC-7-B Ford Specification ................................................ ................................................................................................................................ WSS-M97B51-A1 Add the coolant type originally equipped in your vehicle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transmission Fluid (6R80) .............................................................................................................................................. 11.0 quarts (10.5 liters) NOTE: Indicates only approximate dry fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1605 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION FLUID Motorcraft MERCON LV ATF Ford P/N .............................................................................................................................................. ............................................................... XT-10-QLV Ford Specification ............................................. .............................................................................................................................................. MERCON LV Automatic transmissions that require MERCON LV should only use MERCON LV fluid. Refer to scheduled maintenance information to determine the correct service interval. Use of any fluid other than the recommended fluid may cause transmission damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill Fluid - A/T: Service and Repair Transmission Fluid Drain And Refill 6R80 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 1608 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 1609 - 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 1610 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 1611 Fluid - A/T: Service and Repair Transmission Fluid Exchange 6R80 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 1612 Fluid - A/T: Service and Repair Transmission Fluid Level Check 6R80 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 1613 to check the transmission fluid level. 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/Transmission Fluid Drain And Refill. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Conventional Differential ..................................................................................................................... ..................................................... 4.5 Pints ( 2.13 L ) Limited Slip Differential ................................... ...................................................................................................................................... 4.25 Pints ( 2.01 L ) NOTE: Add 4 oz. (118 ml) of Additive Friction Modifier XL-3 (or equivalent) for complete refill of Ford Limited Slip axles Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1618 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Ford Part Name .................................................................................................................................. Motorcraft SAE 75W-140 Synthetic Rear Axle Lube Ford Part Number ............................................. .......................................................................................................................................... XY-75W140-QL Ford Part Specification .............................................................................................. ................................................................................. WSL-M2C192-A NOTE: Your vehicles rear axle is filled with a synthetic rear axle lubricant and is considered lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is required or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 6.6L (7.0 Qt) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1623 Engine Oil: Fluid Type Specifications Engine Oil U.S.A. ................................................................................................................................... Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada .................................................................................................................................................. Motorcraft SAE 5W-20 Super Premium Motor Oil Ford P/N .............................................................................................................................................. ........................................... XO-5W20-QSP (U.S.A) Ford P/N ............................................................ ...................................................................................................................... CXO-5W20-LSP12 (Canada) Ford Specification ......................................................................................................................................... WSS-M2C930-A with API Certification Mark NOTE: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the requirements of Ford specification WSS-M2C930-A and the API Certification mark. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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.................................................................................................................... ...................................................................0.94 kg (33 oz) (2.07 lb) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1631 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.................................................................................................................... ...................................................................0.94 kg (33 oz) (2.07 lb) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1632 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1635 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1636 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1637 Refrigerant: Service and Repair Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new Thermostatic Expansion Valve (TXV), auxiliary system TXV (if equipped) 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/debris. 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 F8VZ-19E773-AB filter is intended for use on one vehicle only. 1. Remove the condenser core. 2. Remove the plastic receiver/drier cap. 3. Remove the receiver/drier plug. 1. Push the receiver/drier plug upwards and remove the snap ring. 2. Install an M5 bolt in the center of the receiver/drier plug and remove the plug. 4. Using a suitable tool, grasp the receiver/drier cartridge grab handle and remove the receiver/drier cartridge. 5. NOTE: Do not install a new receiver/drier cartridge at this time. With the receiver/drier cartridge removed, reinstall the receiver/drier plug and snap ring into the condenser core. 6. NOTE: Do not evacuate or charge the refrigerant system at this time. NOTE: The RH headlamp assembly must remain removed for access to the condenser outlet fitting. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1638 Install the condenser core back into the vehicle and completely reassemble the vehicle except for the condenser outlet fitting and RH headlamp assembly. 7. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit (219-00074) 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: Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. Using the correct adapters and service hoses, install the pancake filter between the condenser outlet and the condenser outlet fitting. 8. 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. 9. 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. 10. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Start the engine and allow it to idle briefly. Select A/C operation and set the blower speed to HI. Verify that the A/C is operating correctly. 11. If the vehicle is equipped with auxiliary A/C, set the auxiliary system to full COOL at HI blower speed. Verify that the auxiliary A/C is operating correctly. 12. 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. 13. Stop the engine. 14. 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. 15. Remove the pancake filter, hoses and adapter from the vehicle. 16. Remove the condenser core. 17. Remove and discard the receiver/drier plug snap ring and the receiver/drier plug. 18. Install a new receiver/drier cartridge. 19. NOTE: The vehicle should be fully assembled at the completion of this step. Install the condenser core. 20. Evacuate, leak test 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Item.........................................................................................................................................PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D Specification............................................... ..................................................................................................................................................WSHM1C231-B Fill Capacity........................................................................................................................ ......................................207 ml (7 fl oz) See: Service and Repair Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1643 Refrigerant Oil: Fluid Type Specifications Item.........................................................................................................................................PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D Specification............................................... ..................................................................................................................................................WSHM1C231-B Fill Capacity........................................................................................................................ ......................................207 ml (7 fl oz) See: Service and Repair Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1644 Refrigerant Oil: Service and Repair Refrigerant Oil Adding Refrigerant Oil Adding NOTICE: During normal Air Conditioning (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 refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Refer to the chart below for refrigerant oil adding amounts and methods of installation. a If an excessive amount of refrigerant oil is lost due to a hose rupture/separation or other damage, the total system refrigerant oil capacity must be added. b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the refrigerant oil amount by the number of O-ring leaks being repaired. Refrigerant Oil Adding for New A/C Compressor Without Clutch Installation NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. - Add the same amount plus the amount collected during refrigerant recovery. Refrigerant Oil Adding for New A/C Compressor With Clutch Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1645 1. 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. Oil Injection Using a Dye/Lubricant Injector NOTE: The dye/lubricant injector is included as part of the 219-00069 R-134a Loop/Add On Injector Kit-Set. 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 along with the refrigerant 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 using the correct adapters 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 new refrigerant compressor oil. 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 Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1650 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. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1651 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1652 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. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1653 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. 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. 3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the brake pedal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1654 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 Expedition 2wd Workshop Manual (V8-5.4L (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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 switch 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 portion 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. Make sure that all SRS components are connected. 2. Turn the ignition switch from OFF to ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1659 3. Install RCM fuse 32 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will illuminate 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. The flashing might not occur until approximately 30 seconds after the ignition 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 a 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 using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1660 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 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: 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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 portion 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. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column to allow for steering column upper and lower shroud removal. 9. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to the left from the straight-ahead position to access the driver air bag module wire clips and to prevent damage to the steering column multi-function switch. Failure to follow this instruction may result in component damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1661 Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position) as shown. 10. Remove the lower steering column opening cover. - Remove the 3 screws. - Pull out to release the top retainers. - Remove the lower steering column opening cover. If equipped, disconnect the adjustable pedals switch connector. 11. If equipped, remove the screw and steering column manual tilt lever. 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 15. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel. Failure to follow this instruction may result in component damage and/or system failure. NOTE: Steering wheel is removed for clarity. The rear of the steering wheel is shown. NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1662 16. NOTE: Once the driver air bag module is removed, note the position of the 2 driver air bag module locator pins on the steering wheel for installation. Disconnect the driver air bag module and horn switch electrical connectors and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight-ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door to allow access to the passenger air bag electrical connector. - If equipped, disconnect the glove compartment door dampener. 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat. The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical. 21. Release the RH second row safety belt retractor D-ring cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1663 22. Remove the bolt and the RH second row safety belt retractor D-ring. 23. Remove the cover and the RH C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the RH C-pillar trim panel. 25. Disconnect the RH safety canopy module electrical connector. 26. Release the LH second row safety belt retractor D-ring cover. 27. Remove the bolt and the LH second row safety belt retractor D-ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1664 28. Remove the cover and the LH C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver C-pillar trim panel. 30. Disconnect the LH safety canopy module electrical connector. 31. NOTE: There are 2 similar connectors under the driver seat. The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the Smart Junction Box (SJB). 33. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 32 (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 install the driver front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1665 4. Connect the LH safety canopy module electrical connector. 5. Install the LH C-pillar trim panel and attach the rear door weatherstrip. 6. Install the LH C-pillar trim panel nut and cover. 7. Install the LH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the LH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the RH safety canopy module electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1666 10. Install the RH C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger C-pillar trim panel nut and cover. 12. Install the RH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 13. Attach the RH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Extract and retract the safety belt between the full extension and stowed positions. - If excessive effort or binding is present, install a new safety belt buckle retractor and tongue assembly as necessary. For additional information, refer to Seat Belt Systems. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1667 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. NOTICE: The clockspring 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 horn switch and 2 driver air bag module electrical connectors. 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. NOTE: Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. 23. If equipped, install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. If equipped, connect the adjustable pedals switch connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1668 25. Install the lower steering column opening cover and 3 screws. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 32 (10A) to the SJB and install the cover. 28. 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. 29. 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 air bag SRS fault is present, the air bag warning indicator will either: - fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate 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 will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the RCM using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 1674 Fuse: Locations Passenger Compartment Fuse Panel Passenger Compartment Fuse Box 1 - 24 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 1675 25 - 48 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 1676 Fuse: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 1677 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 1678 Fuse: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 1679 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 1680 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1683 Fuse: Application and ID Passenger Compartment Fuse Panel Passenger Compartment Fuse Box 1 - 24 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1684 25 - 48 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1685 Fuse: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1686 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1687 Fuse: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1688 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1689 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1694 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1695 Fuse Block: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1696 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1697 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1698 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1699 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1700 Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 Fuse Block: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 Relay Box: Locations Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1733 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1734 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1735 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1736 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1737 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1738 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1739 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1740 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1741 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 1742 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1745 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1746 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1747 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1748 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1749 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1750 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1751 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1752 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1755 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1756 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1757 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 1758 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Message Center Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value Message Center Cluster NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 1764 Maintenance Required Lamp/Indicator: Reset Procedure Oil Life Reset - Message Center Cluster Message Center Configuration Oil Life Reset - Message Center Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset - Base Instrument Cluster (IC) Message Center Configuration Oil Life Reset - Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value - Message Center Cluster Message Center Configuration Oil Life Start Value - Message Center Cluster NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value - Base Instrument Cluster (IC) Message Center Configuration Oil Life Start Value - Base Instrument Cluster (IC) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 1765 NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Oil Life An oil change is required whenever indicated by the message center. USE ONLY RECOMMENDED ENGINE OILS. To reset the oil monitoring system to 100% after each oil change ( approximately 7,500 miles ( 12,000 km ) or 12 months ) perform the following: 1. Press and release the SETUP control to display "OIL LIFE = XXX% HOLD RESET = NEW". 2. Press and hold the RESET stem for 2 seconds and release. Oil life is set to XX% and "OIL LIFE SET TO XX%" is displayed. Note: Oil Life Start Value of 100% equals 7,500 miles (12,070 km) or 6 months. For example, setting Oil Life Start Value to 60% sets the Oil Life Start Value to 3,000 miles (4,828 km) and 120 days. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Jacking and Lifting Jacking Points - Front WARNING: Shut off the electrical power to the air suspension system prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Failure to follow this instruction may result in serious personal injury. WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions 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: 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. The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel. Jacking Points - Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1776 NOTICE: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire and wheel. Lifting Points - Front and Rear Locate the front hoist adapters and rear hoist adapters as indicated. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1782 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1783 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1786 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1787 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1788 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1789 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1795 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1796 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1799 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1800 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1801 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1802 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 Expedition 2wd Workshop Manual (V8-5.4L (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 parts, 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. Disconnect the wheel speed sensor electrical connector. 2. Remove the wheel and tire. 3. Remove the wheel speed sensor harness bracket bolt and detach the harness from the retainers. - To install, tighten to 12 Nm (106 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1807 4. NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose may result. Remove the 2 bolts and position the caliper and anchor plate aside. - Support the caliper using mechanic's wire. - To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the 4 bolts and the wheel bearing and wheel hub. - Discard the bolts. - To install, tighten to 175 Nm (129 lb-ft). 7. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel speed sensor. - To install, tighten to 18 Nm (159 lb-in). 8. NOTICE: If the original wheel bearing and wheel hub is being installed, a new O-ring seal must be installed or damage to the wheel bearing may occur. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1808 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing and Wheel Hub Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital parts 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 installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1809 1. Remove the wheel and tire. 2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the halfshaft nut. 3. Using a suitable hub puller, 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 may result. Remove the bolts and position the caliper and anchor plate assembly aside. - Support the caliper and anchor plate assembly using mechanic's wire. 5. Remove the brake disc. 6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 7. Remove the 4 bolts, the wheel bearing and wheel hub, and the wheel speed sensor as an assembly. - Route the sensor wiring through the access hole in the brake disc shield. - Discard the bolts. 8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and wheel hub. Installation 1. If necessary, install the wheel speed sensor and bolt. - Tighten to 18 Nm (159 lb-in). 2. Position the wheel bearing and wheel hub, and the wheel speed sensor. Install the 4 new wheel bearing and wheel hub bolts. - Route the sensor wiring through the access hole in the brake disc shield. - Tighten to 175 Nm (129 lb-ft). 3. Attach the wheel speed sensor harness to the retainers and connect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 4. Install the brake disc. 5. Position the caliper and anchor plate assembly and install the bolts. - Tighten to 190 Nm (140 lb-ft). 6. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Install the new halfshaft nut. - Tighten to 300 Nm (221 lb-ft). 7. Install the wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Rear Suspension Wheel Bearing and Wheel Hub Install the new halfshaft nut, tighten to .................................................................................................................................................... 300 Nm (221 lb-ft) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations Wheel Hub Lock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 1817 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 1818 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair Wheel Hub (Locking): Service and Repair Integrated Wheel End (IWE) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire. 3. Remove the dust cap. 4. Remove and discard the axle nut. 5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE). 6. Remove the 3 IWE-to-wheel knuckle retaining bolts. 7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle. - Discard the tie-rod nut. 8. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 9. Remove the front brake flexible hose bracket bolt and position the brake hose aside. 10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle. - Discard the upper ball joint nut. 11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing. 12. Remove the IWE from the halfshaft outboard end. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Page 1822 1. Compress the IWE and install a vacuum cap on the vacuum port. 2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE on halfshaft outboard end or component damage may occur. Install the IWE onto the halfshaft outboard end. 3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing. 4. Connect the upper ball joint and install a new nut. - Tighten to 115 Nm (85 lb-ft). 5. Connect the tie rod and install a new nut. - Tighten to 115 Nm (85 lb-ft). 6. Position the front brake flexible hose bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the wheel speed sensor harness bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 8. Install the 3 IWE-to-wheel knuckle retaining bolts. - Tighten to 12 Nm (106 lb-in). 9. Remove the IWE vacuum cap and connect the vacuum tubes. 10. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle nut or component damage may occur. Install the new axle nut. - Tighten to 27 Nm (20 lb-ft). 11. Install the dust cap. 12. Install the front wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Tighten the wheel nuts in a star/cross pattern. Tighten to.................................................................... ...............................................................................................................................135 Nm (100 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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 parts, 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. NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the brake hose or damage to the hose may result. Remove the 2 bolts and position the brake caliper and anchor plate assembly aside. - Support the brake caliper and anchor plate assembly using mechanic's wire. 3. Remove the brake disc. 4. Using the C-Frame and Screw Assembly, remove the wheel stud. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1828 Installation 1. 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. Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by the original wheel stud. - Place 4 washers over the outside end of the wheel stud and thread a standard wheel nut onto the wheel stud with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the wheel hub flange. 2. Remove the wheel nut and washers. 3. Install the brake disc. 4. Position the brake caliper and anchor plate assembly and install the bolts. - Tighten the bolts to 200 Nm (148 lb-ft). 5. Install the wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1829 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 correct retention of these parts. 1. 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. 2. NOTICE: Never use a hammer to remove a wheel stud. Damage to the wheel hub may result. Place the wheel hub in a soft-jawed vise and, using the C-Frame and Screw, remove the wheel stud. Installation 1. Position the new wheel stud in the wheel bearing and hub assembly, aligning the serrations in the wheel hub flange made by the original wheel stud. 2. NOTICE: Do not use power tools to install the wheel stud. The serrations on the flange 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 4 washers and a wheel nut on the wheel stud and tighten the wheel nut until the stud seats against the flange. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1830 3. Remove the wheel nut and washers. - Discard the wheel nut. 4. Install the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Rear Suspension. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Jacking and Lifting Jacking Points - Front WARNING: Shut off the electrical power to the air suspension system prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Failure to follow this instruction may result in serious personal injury. WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions 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: 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. The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel. Jacking Points - Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 1834 NOTICE: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire and wheel. Lifting Points - Front and Rear Locate the front hoist adapters and rear hoist adapters as indicated. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise Variable Valve Timing Actuator: Customer Interest Engine - Low Frequency Hot Idle Knocking Noise TSB 10-18-4 09/27/10 LOW FREQUENCY ENGINE KNOCKING NOISE AT HOT IDLE FORD: 2009-2010 Expedition, F-150, F-250, F-350 LINCOLN: 2009-2010 Navigator This article supersedes TSB 09-23-7 to update the vehicle model lines, Service Procedure and Service Labor Time Standards. ISSUE Some 2009-2010 F-150 and F-Super Duty vehicles equipped with a 4.6L 3V or 5.4L 3V engine, Expedition and Navigator vehicles may exhibit a low frequency knocking noise from the engine at hot idle only. The noise is predominately heard from the right front wheel well area and/or the right hand (RH) engine cam cover. This noise may be generated from the RH variable camshaft timing (VCT) phaser assembly. This procedure was created to diagnose the RH VCT phaser assembly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The Integrated Diagnostic System (IDS) tests were developed specifically for the vehicles and Power Control Module (PCM) strategies for these vehicles. Per Workshop Manual (WSM), Powertrain Controls and Emissions Diagnostics (PC/ED) and Scheduled Maintenance Guide, review customer service history for use of any aftermarket oil filters. 1. Check for possible diagnostic trouble codes (DTCs). a. No DTCs present, proceed to Step 2. b. If DTCs are present, do not continue with this procedure and refer to the PC/ED manual for diagnostics. 2. Engine must be at full operating temperature over 190 °F (88 °C) cylinder head temperature (CHT). 3. Connect IDS diagnostics tool and verify software version is at the latest level (63 or later required). 4. Begin a new vehicle session. 5. Open Tool Box selection. 6. Open Data Logger. 7. Select Powertrain Engine. 8. Select PCM Data Logger. 9. Clear the preselected items by clicking the eraser icon button. 10. Select variable cam timing desired angle number (VCLDSD). 11. Go to live display and press the tick mark. 12. Make sure the parameter identification (PID) is highlighted with the dark lines above and below the data being displayed. 13. Press number symbol: (output state control mode) of the VCT_DSD number PID. 14. Press the Control Item Activate (finger on the button) icon to enable manual control of the PID. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise > Page 1846 15. Use the plus button to command to 4 degrees. (One click is equal to 1 degree) When commanding the advance, both banks will normally adjust. 16. Listen carefully to the low frequency knock noise while commanding the VCT_DSD from 0 to 4 degrees. Some higher frequency clatter is normal at or above the 5 degree advance. What is being pursued is for the level of the low frequency knock noise to be noticeably reduced when advanced from 4 to 5 degrees. a. If noise level is noticeably reduced as the VCT desired angle is commanded from 3 to 4 degrees, the noise source is the RH VCT phaser assembly. Proceed to Step 17. b. If the low frequency knock noise is not noticeably reduced at 4 degrees, refer to WSM, Section 303-00 for engine noise diagnostics. 17. Due to normal engine dynamics, the VCT phaser knock noise is produced by the RH VCT phaser assembly. Replace only the RH VCT phaser assembly. Refer to WSM, Section 303-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT:Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101804A 2009-2010 Expedition, 2.3 Hrs Navigator 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150 4.6L 3V: 1.8 Hrs. Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150, F-Super 2.1 Hrs. Duty 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6A257 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Low Frequency Hot Idle Knocking Noise TSB 10-18-4 09/27/10 LOW FREQUENCY ENGINE KNOCKING NOISE AT HOT IDLE FORD: 2009-2010 Expedition, F-150, F-250, F-350 LINCOLN: 2009-2010 Navigator This article supersedes TSB 09-23-7 to update the vehicle model lines, Service Procedure and Service Labor Time Standards. ISSUE Some 2009-2010 F-150 and F-Super Duty vehicles equipped with a 4.6L 3V or 5.4L 3V engine, Expedition and Navigator vehicles may exhibit a low frequency knocking noise from the engine at hot idle only. The noise is predominately heard from the right front wheel well area and/or the right hand (RH) engine cam cover. This noise may be generated from the RH variable camshaft timing (VCT) phaser assembly. This procedure was created to diagnose the RH VCT phaser assembly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The Integrated Diagnostic System (IDS) tests were developed specifically for the vehicles and Power Control Module (PCM) strategies for these vehicles. Per Workshop Manual (WSM), Powertrain Controls and Emissions Diagnostics (PC/ED) and Scheduled Maintenance Guide, review customer service history for use of any aftermarket oil filters. 1. Check for possible diagnostic trouble codes (DTCs). a. No DTCs present, proceed to Step 2. b. If DTCs are present, do not continue with this procedure and refer to the PC/ED manual for diagnostics. 2. Engine must be at full operating temperature over 190 °F (88 °C) cylinder head temperature (CHT). 3. Connect IDS diagnostics tool and verify software version is at the latest level (63 or later required). 4. Begin a new vehicle session. 5. Open Tool Box selection. 6. Open Data Logger. 7. Select Powertrain Engine. 8. Select PCM Data Logger. 9. Clear the preselected items by clicking the eraser icon button. 10. Select variable cam timing desired angle number (VCLDSD). 11. Go to live display and press the tick mark. 12. Make sure the parameter identification (PID) is highlighted with the dark lines above and below the data being displayed. 13. Press number symbol: (output state control mode) of the VCT_DSD number PID. 14. Press the Control Item Activate (finger on the button) icon to enable manual control of the PID. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise > Page 1852 15. Use the plus button to command to 4 degrees. (One click is equal to 1 degree) When commanding the advance, both banks will normally adjust. 16. Listen carefully to the low frequency knock noise while commanding the VCT_DSD from 0 to 4 degrees. Some higher frequency clatter is normal at or above the 5 degree advance. What is being pursued is for the level of the low frequency knock noise to be noticeably reduced when advanced from 4 to 5 degrees. a. If noise level is noticeably reduced as the VCT desired angle is commanded from 3 to 4 degrees, the noise source is the RH VCT phaser assembly. Proceed to Step 17. b. If the low frequency knock noise is not noticeably reduced at 4 degrees, refer to WSM, Section 303-00 for engine noise diagnostics. 17. Due to normal engine dynamics, the VCT phaser knock noise is produced by the RH VCT phaser assembly. Replace only the RH VCT phaser assembly. Refer to WSM, Section 303-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT:Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101804A 2009-2010 Expedition, 2.3 Hrs Navigator 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150 4.6L 3V: 1.8 Hrs. Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150, F-Super 2.1 Hrs. Duty 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6A257 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 1853 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 1854 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Variable Camshaft Timing (VCT) Solenoid 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Variable Camshaft Timing (VCT) Solenoid 1 > Page 1859 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Variable Camshaft Timing (VCT) Solenoid 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Variable Camshaft Timing (VCT) Solenoid 1 > Page 1862 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Page 1863 Variable Valve Timing Solenoid: Service and Repair Variable Camshaft Timing (VCT) Oil Control Solenoid NOTE: LH shown, RH similar. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1867 Compression Check: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1868 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Tighten to.............................................................................................................................................. ....................10 Nm (89 lb-in) in the sequence shown. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages. Stage 1: Tighten to................................................................................................................ .........................................................................40 Nm (30 lb-ft). Stage 2: Tighten an additional.......... .............................................................................................................................................................. .........90 degrees. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1880 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1881 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1882 Camshaft: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Camshaft - LH Camshaft - LH Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1883 Removal NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons will result. 1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 2. Remove the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Loosen and back off the LH camshaft phaser and sprocket bolt one full turn. 4. Disconnect the LH Camshaft Position (CMP) sensor electrical connector. 5. Remove the bolt and the LH CMP sensor. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1884 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will require one full additional rotation to 12 o'clock. The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder. 7. Remove only the 3 camshaft roller followers shown in the illustration. 8. NOTICE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1885 9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position. 10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the Timing Chain Locking Tool in the LH timing chain as shown. 11. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1886 12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Remove the 2 bolts and the LH camshaft front bearing cap. 13. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining 8 bolts in the sequence shown and remove the 4 camshaft bearing caps. 14. Clean and inspect the LH camshaft bearing caps. - The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. 15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1887 - Discard the bolt and washer. 16. Remove the camshaft. 17. Remove and inspect the camshaft phaser and sprocket for damage. Installation 1. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft. 2. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket. Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment. 3. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight. 4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the 5 camshaft bearing caps in their original locations. - Lubricate the camshaft bearing caps with clean engine oil. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1888 - Position the 2 front camshaft bearing cap. - Position the remaining 8 camshaft bearing caps. - Install the 10 bolts loosely. 5. Tighten the bolts in the sequence shown. - Tighten to 10 Nm (89 lb-in). 6. NOTE: Engine front cover removed for clarity. Remove the Timing Chain Locking Tool. 7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 8. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust camshaft lobes. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1889 9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers. 10. Install the CMP sensor and the bolt. - Tighten to 10 Nm (89 lb-in). 11. Connect the CMP electrical connector. 12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the camshaft phaser and sprocket bolt in 2 stages: - Stage 1: Tighten to 40 Nm (30 lb-ft). - Stage 2: Tighten an additional 90 degrees. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1890 13. Install the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. Camshaft - RH Camshaft - RH Removal NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons will result. 1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 2. Remove the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn. 4. Disconnect the RH Camshaft Position (CMP) sensor electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1891 5. Remove the bolt and the RH CMP sensor. 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder. 7. Remove only the 3 camshaft roller followers shown in the illustration. 8. NOTICE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1892 9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position. 10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the Timing Chain Locking Tool in the RH timing chain as shown. 11. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly. 12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1893 from side loading. Remove the 2 bolts and the front camshaft bearing cap. 13. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining bolts in the sequence shown and remove the remaining camshaft bearing caps. 14. Clean and inspect the RH camshaft bearing caps. - The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. 15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft. - Discard the bolt and washer. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1894 16. Remove the camshaft. 17. Remove and inspect the camshaft phaser and sprocket for damage. Installation 1. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft. 2. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket. Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment. 3. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight. 4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the 5 camshaft bearing caps in their original locations. - Lubricate the camshaft bearing caps with clean engine oil. - Position the front camshaft bearing cap. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1895 - Position the remaining camshaft bearing caps. - Install the 10 bolts loosely. 5. Tighten the 10 bolts in the sequence shown. - Tighten to 10 Nm (89 lb-in). 6. NOTE: Engine front cover removed for clarity. Remove the Timing Chain Locking Tool. 7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 8. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust camshaft lobes. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1896 9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers. 10. Install the CMP sensor and the bolt. - Tighten to 10 Nm (89 lb-in). 11. Connect the CMP electrical connector. 12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the new camshaft phaser and sprocket bolt in 2 stages: - Stage 1: Tighten to 40 Nm (30 lb-ft). - Stage 2: Tighten an additional 90 degrees. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1897 13. Install the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. Camshaft Phaser And Sprocket - LH Camshaft Phaser and Sprocket - LH Removal NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons will result. 1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 2. Remove the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Loosen and back off the LH camshaft phaser and sprocket bolt one full turn. 4. Disconnect the LH Camshaft Position (CMP) sensor electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1898 5. Remove the bolt and the LH CMP sensor. 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will require one full additional rotation to 12 o'clock. The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder. 7. Remove only the 3 camshaft roller followers shown in the illustration. 8. NOTICE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1899 9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position. 10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTICE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine block or damage may result. NOTE: Engine front cover removed for clarity. Install the Timing Chain Locking Tool in the LH timing chain as shown. 11. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1900 12. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft. - Discard the bolt and washer. 13. Remove the camshaft phaser and sprocket assembly from the timing chain and inspect for damage. Installation 1. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket. Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment. 2. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1901 3. NOTE: Engine front cover removed for clarity. Remove the Timing Chain Locking Tool. 4. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 5. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust camshaft lobes. 6. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1902 7. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the CMP sensor and the bolt. - Tighten to 10 Nm (89 lb-in). 8. Connect the CMP electrical connector. 9. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the camshaft phaser and sprocket bolt in 2 stages: - Stage 1: Tighten to 40 Nm (30 lb-ft). - Stage 2: Tighten an additional 90 degrees. 10. Install the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. Camshaft Phaser And Sprocket - RH Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1903 Camshaft Phaser and Sprocket - RH Removal NOTICE: This procedure must be followed exactly or damage to the valves and pistons will result. 1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 2. Remove the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn. 4. Disconnect the RH Camshaft Position (CMP) sensor electrical connector. 5. Remove the bolt and the RH CMP sensor. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1904 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder. 7. Remove only the 3 camshaft roller followers shown in the illustration. 8. NOTICE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step. 9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1905 10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the Timing Chain Locking Tool in the RH timing chain as shown. 11. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly. 12. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. Remove the bolt and remove the camshaft phaser and sprocket assembly from camshaft. - Discard the bolt and washer. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1906 13. Remove the camshaft phaser and sprocket assembly from the timing chain and inspect for damage. Installation 1. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket. Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment. 2. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight. 3. NOTE: Engine front cover removed for clarity. Remove the Timing Chain Locking Tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1907 4. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 5. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust camshaft lobes. 6. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers. 7. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the CMP sensor and the bolt. - Tighten to 10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1908 8. Connect the CMP electrical connector. 9. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the new camshaft phaser and sprocket bolt in 2 stages: - Stage 1: Tighten to 40 Nm (30 lb-ft). - Stage 2: Tighten an additional 90 degrees. 10. Install the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1913 Lifter / Lash Adjuster: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Hydraulic Lash Adjuster Hydraulic Lash Adjuster Removal and Installation RH cylinder head hydraulic lash adjusters 1. Remove the RH camshaft. For additional information, refer to Camshaft - RH See: Camshaft/Service and Repair/Removal and Replacement/Camshaft - RH. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1914 LH cylinder head hydraulic lash adjusters 2. Remove the LH camshaft. For additional information, refer to Camshaft - LH See: Camshaft/Service and Repair/Removal and Replacement/Camshaft - LH. All hydraulic lash adjusters 3. Remove the camshaft roller follower from the hydraulic lash adjuster being serviced. 4. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. Remove the hydraulic lash adjuster that is being serviced. 5. Inspect the hydraulic lash adjuster. 6. NOTE: Lubricate the hydraulic lash adjuster with clean engine oil prior to installation. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1919 Rocker Arm Assembly: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Camshaft Roller Follower Camshaft Roller Follower Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1920 Removal LH cylinder head camshaft roller followers 1. Remove the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. RH cylinder head camshaft roller followers 2. Remove the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. All camshaft roller followers 3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed. 4. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower. 5. Repeat the previous 2 steps for each camshaft roller follower being serviced. 6. Inspect the camshaft roller follower. Installation All camshaft roller followers 1. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1921 2. Repeat the previous step for each camshaft roller follower being serviced. LH cylinder head camshaft roller followers 3. Install the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. RH cylinder head camshaft roller followers 4. Install the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise Variable Valve Timing Actuator: Customer Interest Engine - Low Frequency Hot Idle Knocking Noise TSB 10-18-4 09/27/10 LOW FREQUENCY ENGINE KNOCKING NOISE AT HOT IDLE FORD: 2009-2010 Expedition, F-150, F-250, F-350 LINCOLN: 2009-2010 Navigator This article supersedes TSB 09-23-7 to update the vehicle model lines, Service Procedure and Service Labor Time Standards. ISSUE Some 2009-2010 F-150 and F-Super Duty vehicles equipped with a 4.6L 3V or 5.4L 3V engine, Expedition and Navigator vehicles may exhibit a low frequency knocking noise from the engine at hot idle only. The noise is predominately heard from the right front wheel well area and/or the right hand (RH) engine cam cover. This noise may be generated from the RH variable camshaft timing (VCT) phaser assembly. This procedure was created to diagnose the RH VCT phaser assembly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The Integrated Diagnostic System (IDS) tests were developed specifically for the vehicles and Power Control Module (PCM) strategies for these vehicles. Per Workshop Manual (WSM), Powertrain Controls and Emissions Diagnostics (PC/ED) and Scheduled Maintenance Guide, review customer service history for use of any aftermarket oil filters. 1. Check for possible diagnostic trouble codes (DTCs). a. No DTCs present, proceed to Step 2. b. If DTCs are present, do not continue with this procedure and refer to the PC/ED manual for diagnostics. 2. Engine must be at full operating temperature over 190 °F (88 °C) cylinder head temperature (CHT). 3. Connect IDS diagnostics tool and verify software version is at the latest level (63 or later required). 4. Begin a new vehicle session. 5. Open Tool Box selection. 6. Open Data Logger. 7. Select Powertrain Engine. 8. Select PCM Data Logger. 9. Clear the preselected items by clicking the eraser icon button. 10. Select variable cam timing desired angle number (VCLDSD). 11. Go to live display and press the tick mark. 12. Make sure the parameter identification (PID) is highlighted with the dark lines above and below the data being displayed. 13. Press number symbol: (output state control mode) of the VCT_DSD number PID. 14. Press the Control Item Activate (finger on the button) icon to enable manual control of the PID. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise > Page 1930 15. Use the plus button to command to 4 degrees. (One click is equal to 1 degree) When commanding the advance, both banks will normally adjust. 16. Listen carefully to the low frequency knock noise while commanding the VCT_DSD from 0 to 4 degrees. Some higher frequency clatter is normal at or above the 5 degree advance. What is being pursued is for the level of the low frequency knock noise to be noticeably reduced when advanced from 4 to 5 degrees. a. If noise level is noticeably reduced as the VCT desired angle is commanded from 3 to 4 degrees, the noise source is the RH VCT phaser assembly. Proceed to Step 17. b. If the low frequency knock noise is not noticeably reduced at 4 degrees, refer to WSM, Section 303-00 for engine noise diagnostics. 17. Due to normal engine dynamics, the VCT phaser knock noise is produced by the RH VCT phaser assembly. Replace only the RH VCT phaser assembly. Refer to WSM, Section 303-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT:Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101804A 2009-2010 Expedition, 2.3 Hrs Navigator 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150 4.6L 3V: 1.8 Hrs. Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150, F-Super 2.1 Hrs. Duty 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6A257 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Low Frequency Hot Idle Knocking Noise TSB 10-18-4 09/27/10 LOW FREQUENCY ENGINE KNOCKING NOISE AT HOT IDLE FORD: 2009-2010 Expedition, F-150, F-250, F-350 LINCOLN: 2009-2010 Navigator This article supersedes TSB 09-23-7 to update the vehicle model lines, Service Procedure and Service Labor Time Standards. ISSUE Some 2009-2010 F-150 and F-Super Duty vehicles equipped with a 4.6L 3V or 5.4L 3V engine, Expedition and Navigator vehicles may exhibit a low frequency knocking noise from the engine at hot idle only. The noise is predominately heard from the right front wheel well area and/or the right hand (RH) engine cam cover. This noise may be generated from the RH variable camshaft timing (VCT) phaser assembly. This procedure was created to diagnose the RH VCT phaser assembly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The Integrated Diagnostic System (IDS) tests were developed specifically for the vehicles and Power Control Module (PCM) strategies for these vehicles. Per Workshop Manual (WSM), Powertrain Controls and Emissions Diagnostics (PC/ED) and Scheduled Maintenance Guide, review customer service history for use of any aftermarket oil filters. 1. Check for possible diagnostic trouble codes (DTCs). a. No DTCs present, proceed to Step 2. b. If DTCs are present, do not continue with this procedure and refer to the PC/ED manual for diagnostics. 2. Engine must be at full operating temperature over 190 °F (88 °C) cylinder head temperature (CHT). 3. Connect IDS diagnostics tool and verify software version is at the latest level (63 or later required). 4. Begin a new vehicle session. 5. Open Tool Box selection. 6. Open Data Logger. 7. Select Powertrain Engine. 8. Select PCM Data Logger. 9. Clear the preselected items by clicking the eraser icon button. 10. Select variable cam timing desired angle number (VCLDSD). 11. Go to live display and press the tick mark. 12. Make sure the parameter identification (PID) is highlighted with the dark lines above and below the data being displayed. 13. Press number symbol: (output state control mode) of the VCT_DSD number PID. 14. Press the Control Item Activate (finger on the button) icon to enable manual control of the PID. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise > Page 1936 15. Use the plus button to command to 4 degrees. (One click is equal to 1 degree) When commanding the advance, both banks will normally adjust. 16. Listen carefully to the low frequency knock noise while commanding the VCT_DSD from 0 to 4 degrees. Some higher frequency clatter is normal at or above the 5 degree advance. What is being pursued is for the level of the low frequency knock noise to be noticeably reduced when advanced from 4 to 5 degrees. a. If noise level is noticeably reduced as the VCT desired angle is commanded from 3 to 4 degrees, the noise source is the RH VCT phaser assembly. Proceed to Step 17. b. If the low frequency knock noise is not noticeably reduced at 4 degrees, refer to WSM, Section 303-00 for engine noise diagnostics. 17. Due to normal engine dynamics, the VCT phaser knock noise is produced by the RH VCT phaser assembly. Replace only the RH VCT phaser assembly. Refer to WSM, Section 303-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT:Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101804A 2009-2010 Expedition, 2.3 Hrs Navigator 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150 4.6L 3V: 1.8 Hrs. Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150, F-Super 2.1 Hrs. Duty 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6A257 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 1937 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 1938 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Cover / Housing > Component Information > Service and Repair > Procedures Variable Valve Timing Cover / Housing: Procedures 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Cover / Housing > Component Information > Service and Repair > Procedures > Page 1943 Variable Valve Timing Cover / Housing: Removal and Replacement Variable Camshaft Timing (VCT) Housing Removal All Variable Camshaft Timing (VCT) housings 1. Remove the timing drive components. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. RH VCT housing 2. Remove the 2 bolts and the RH Variable Camshaft Timing (VCT) housing. LH VCT housing 3. Remove the 2 bolts and the LH VCT housing. All VCT housings 4. Remove and discard the VCT housing gasket. 5. 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 old sealant. Clean and inspect the cylinder head sealing surfaces with metal surface prep. Follow the directions on the packaging. 6. Clean and inspect the VCT housing. Installation All VCT housing Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Cover / Housing > Component Information > Service and Repair > Procedures > Page 1944 1. Install a new gasket onto the VCT housing. RH VCT housing 2. Position the RH VCT housing and install the 2 bolts. - Tighten to 10 Nm (89 lb-in). LH VCT housing 3. Position the LH VCT housing and install the 2 bolts. - Tighten to 10 Nm (89 lb-in). All VCT housings 4. Install the timing drive components. For additional information, refer to Timing Drive Components See: Timing Components/Service and Repair/Removal and Replacement. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1949 a The time required for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down fluid in the lash adjuster. b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1950 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications CONNECTING ROD Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1954 a The time required for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down fluid in the lash adjuster. b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline. ROD BEARING CAP Tighten the 16 bolts in 2 stages, in the sequence shown. Stage 1: Tighten to.................................... .....................................................................................................................................................43 Nm (32 lb-ft). Stage 2: Tighten an additional........................................................................................ .......................................................................................105 degrees. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1955 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1958 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1959 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1960 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1961 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1962 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1963 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1964 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications a The time required for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down fluid in the lash adjuster. b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline. MAIN BEARING CAP Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1968 Install the 10 vertical main bearing cap fasteners and tighten in 2 stages, in the sequence shown. Stage 1: Tighten to............................................................................................................................... ..........................................................40 Nm (30 lb-ft). Stage 2: Tighten an additional......................... ........................................................................................................................................................90 degrees. Install the 10 side bolts and tighten them in 2 stages, in the sequence shown. Stage 1: Tighten to ... .............................................................................................................................................................. ..................... 30 Nm (22 lb-ft). Stage 2: Tighten ................................................................................. ............................................................................................. an additional 90 degrees. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1969 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1970 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications a The time required for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down fluid in the lash adjuster. b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1976 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1977 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1978 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 Expedition 2wd Workshop Manual (V8-5.4L (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. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair/Cooling System Draining, Filling And Bleeding. 2. NOTE: Do not loosen the block heater retaining screw more than necessary for removal. Loosen the block heater retaining screw and remove the block heater. - To install, tighten to 2 Nm (18 lb-in). 3. NOTICE: Route the block heater power cable away from hot or rotating components, or damage to the cable can occur. NOTE: Lubricate the block heater O-ring seal with clean engine coolant prior to installation. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Tighten the new crankshaft pulley bolt in 4 stages. Stage 1: Tighten to.............................................. ...........................................................................................................................................90 Nm (66 lb-ft). Stage 2: Loosen.......................................................................................................................... ...........................................................................360 degrees. Stage 3: Tighten to.............................. ...........................................................................................................................................................5 0 Nm (37 lb-ft). Stage 4: Tighten an additional..................................................................................... ............................................................................................90 degrees. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1985 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the cooling fan. 3. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1986 4. Remove the crankshaft pulley bolt and washer. - Discard the crankshaft pulley bolt. 5. Using the 3-Jaw Puller, remove the crankshaft pulley. Installation 1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley. 2. Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation. 3. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley. 4. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. - Stage 1: Tighten to 90 Nm (66 lb-ft). - Stage 2: Loosen 360 degrees. - Stage 3: Tighten to 50 Nm (37 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1987 - Stage 4: Tighten an additional 90 degrees. 5. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley. 6. Install the cooling fan. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications a The time required for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down fluid in the lash adjuster. b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1993 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. - Refer to the appropriate system for the procedure. Piston Ring End Gap Piston Ring End Gap Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1994 NOTICE: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1995 Piston Pin Diameter 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1996 Piston: Overhaul Piston Disassembly WARNING: Since the retainer ring has a tendency to spring out, cover the end of the pin bore with a hand or shop rag when removing the ring. Wear eye protection. Failure to follow these instructions may result in serious personal injury. 1. Remove the piston rings from the piston. - Discard the piston rings. 2. Mark the piston and connecting rod on the same side for assembly reference. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1997 3. Remove the 2 piston pin retainers and the piston pin. 4. Separate the piston from the connecting rod. 5. Clean and inspect the piston and connecting rod. Assembly 1. NOTE: The connecting rod must be installed into the piston with the marks made during disassembly on the same side. If a new piston or connecting rod is being installed, it can be installed in either direction. Position the connecting rod in the piston. 2. Lubricate the piston pin and pin bore with clean engine oil. 3. Install the piston pin in the piston and connecting rod assembly. 4. Install the 2 piston pin retaining clips in the piston. 5. Lubricate the piston and the new piston rings with clean engine oil. 6. Install the piston rings onto the piston. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications a The time required for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down fluid in the lash adjuster. b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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: 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. 1. Disconnect the battery ground cable. 2. Remove the cap from the fuel pressure relief valve located on the fuel rail. 3. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 4. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the Fuel Pressure Test Kit and relieve the fuel pressure. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 2005 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2010 Rocker Arm Assembly: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Camshaft Roller Follower Camshaft Roller Follower Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2011 Removal LH cylinder head camshaft roller followers 1. Remove the LH valve cover. For additional information, refer to Valve Cover - LH See: Valve Cover/Service and Repair/Valve Cover - LH. RH cylinder head camshaft roller followers 2. Remove the RH valve cover. For additional information, refer to Valve Cover - RH See: Valve Cover/Service and Repair/Valve Cover - RH. All camshaft roller followers 3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed. 4. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Service and Repair/Removal and Replacement/Cylinder Head Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower. 5. Repeat the previous 2 steps for each camshaft roller follower being serviced. 6. Inspect the camshaft roller follower. Installation All camshaft roller followers 1. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Service and Repair/Removal and Replacement/Cylinder Head Removal. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2012 2. Repeat the previous step for each camshaft roller follower being serviced. LH cylinder head camshaft roller followers 3. Install the LH valve cover. For additional information, refer to Valve Cover - LH See: Valve Cover/Service and Repair/Valve Cover - LH. RH cylinder head camshaft roller followers 4. Install the RH valve cover. For additional information, refer to Valve Cover - RH See: Valve Cover/Service and Repair/Valve Cover - RH. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 PCV Tube, Engine Wiring Harness Retainers and Variable Camshaft Timing (VCT) Solenoid Electrical Connector Engine Wiring Harness Retainers, Intake Manifold Vacuum Tube, LH Valve Cover and Gasket Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2017 Removal 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Remove the bolt and position the oil level indicator and tube aside. 3. Disconnect the quick connect couplings and remove the PCV tube. 4. Disconnect the intake manifold vacuum tube hose from the brake booster. 5. Disconnect the intake manifold vacuum tube from the support bracket and the valve cover stud. 6. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector. 7. Disconnect the 3 wiring harness retainers from the front of the LH valve cover and the 2 wiring harness retainers from the LH valve cover studs. 8. Remove the 4 LH ignition coils. 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 old sealant. NOTICE: When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid. NOTE: The fasteners are part of the valve cover and should not be removed. Loosen the 10 fasteners and remove the LH valve cover and gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. - Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. Installation 1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. 2. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid. Position the LH valve cover and new gasket on the cylinder head and tighten the 10 fasteners in the sequence shown. - Tighten to 10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2018 3. Position the intake manifold vacuum tube assembly onto the support bracket and the valve cover stud. 4. Connect the intake manifold vacuum tube hose to the brake booster. 5. Install the 4 LH ignition coils. 6. Connect the 3 wiring harness retainers to the front of the RH valve cover and the 2 wiring harness retainers to the RH valve cover studs. 7. Connect the VCT solenoid electrical connector. 8. Position the PCV tube and connect the quick connect couplings. 9. Position back the oil level indicator and tube and install the bolt. - Tighten to 10 Nm (89 lb-in). 10. Install the ACL outlet pipe. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2019 Valve Cover: Service and Repair Valve Cover - RH Valve Cover - RH Engine Wiring Harness Retainers, Variable Camshaft Timing (VCT) Solenoid Electrical Connector, Crankcase Ventilation Tube, RH Valve Cover and Gasket Removal Vehicles with auxiliary heat 1. Drain the cooling system. 2. Disconnect the 2 auxiliary heat coolant hoses and position the auxiliary heat coolant hoses aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2020 All vehicles 3. Disconnect the quick connect couplings and remove the crankcase vent tube. 4. Disconnect the PCM electrical connector and position aside. 5. Remove the nut and the ground cable and disconnect the wiring harness retainer. 6. Disconnect the PCM electrical connector. 7. Disconnect the 2 electrical connectors and the wiring harness retainer and position the wiring harness aside. 8. Disconnect the RH radio ignition interference capacitor and engine cooling fan clutch electrical connectors. 9. Remove the 4 RH ignition coils. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2021 10. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector. 11. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs and position the wiring harness aside. 12. 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 old sealant. NOTICE: When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid. NOTE: The fasteners are part of the valve cover and should not be removed. Loosen the 9 fasteners and remove the RH valve cover and gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. - Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. Installation All vehicles 1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. 2. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid. Position the RH valve cover and new gasket on the cylinder head and tighten the 9 fasteners in the sequence shown. - Tighten to 10 Nm (89 lb-in). 3. Install the 4 RH ignition coils. 4. Position back the engine wiring harness and connect the 2 electrical connectors and the wiring harness retainer. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2022 5. Connect the PCM electrical connector. 6. Connect the wiring harness retainer and ground cable and install the nut. - Tighten to 10 Nm (89 lb-in). 7. Connect the PCM electrical connector. 8. Connect the RH radio ignition interference capacitor and engine cooling fan clutch electrical connectors. 9. Connect the RH VCT solenoid electrical connector. 10. Connect the wiring harness retainers to the valve cover. 11. Position the crankcase vent tube and connect the quick connect couplings. Vehicles with auxiliary heat 12. Connect the 2 auxiliary heat coolant hoses. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2023 13. Fill and bleed the coolant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2031 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2032 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2037 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2038 Valve Spring: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Valve Springs Valve Springs Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2039 Removal RH cylinder head valve springs 1. Remove the RH valve cover. For additional information, refer to Valve Cover - RH See: Valve Cover/Service and Repair/Valve Cover - RH. LH cylinder head valve springs 2. Remove the LH valve cover. For additional information, refer to Valve Cover - LH See: Valve Cover/Service and Repair/Valve Cover - LH. All valve springs 3. Remove the spark plug for the cylinder being serviced. 4. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed. 5. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Service and Repair/Removal and Replacement/Cylinder Head Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower. 6. Use compressed air in the cylinder being serviced to hold both valves in position. - Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder. 7. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: 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. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to Cylinder Head See: Service and Repair/Removal and Replacement/Cylinder Head Removal. Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys. 8. Remove the valve spring retainer and the valve spring. 9. Inspect the valve spring. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2040 Installation All valve springs 1. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage. Using the Valve Spring Compressor, install the valve spring, the valve spring retainer and the valve spring retainer keys. 2. Relieve the air pressure from the cylinder. 3. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow this instruction may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Service and Repair/Removal and Replacement/Cylinder Head Removal. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower. 4. Install the spark plug. LH cylinder head valve springs 5. Install the LH valve cover. For additional information, refer to Valve Cover - LH See: Valve Cover/Service and Repair/Valve Cover - LH. RH cylinder head valve springs 6. Install the RH valve cover. For additional information, refer to Valve Cover - RH See: Valve Cover/Service and Repair/Valve Cover - RH. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 2045 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 2046 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Accessory Drive Belt Routing Front End Accessory Drive (FEAD) Components Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Component Tests 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2053 Drive Belt: Testing and Inspection Drive Belt - Incorrect Installation Accessory Drive Component Tests 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2056 Drive Belt: Service and Repair Accessory Drive Belt Accessory Drive Belt Removal and Installation 1. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 2. NOTE: Make sure the drive belt is correctly installed on each pulley. To install, reverse the removal procedure. - Refer to Accessory Drive See: Description and Operation in Description and Operation for drive belt routing. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 portion. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2061 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2064 Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Accessory Drive Belt Tensioner Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pushpin, press the position retaining tab and rotate the lower cooling fan shroud upward until the position retainer tab locks into position. 3. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the A/C compressor pulley. 4. Remove the 3 bolts and the accessory drive belt tensioner. - To install, tighten to 25 Nm (18 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2069 Engine Mount: Removal and Replacement Engine Support Insulators LH Engine Support Insulator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2070 RH Engine Support Insulator Removal All engine support insulators 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the Throttle Body (TB). 4. Remove the cooling fan. 5. Remove the generator. 6. Remove the starter. 7. If servicing the engine support insulators on a Four-Wheel Drive (4WD) vehicle, remove the front drive shaft. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2071 8. Install the Engine Support Bar, Support Hook and Engine Support Bracket. 9. Remove the 4 (2 RH and 2 LH) Y-pipe flange nuts. 10. NOTICE: Only use hand tools when removing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur. Loosen the 2 transmission mount-to-crossmember nuts. RH engine support insulator 11. NOTICE: Only use hand tools when loosening the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Loosen the LH engine support insulator through bolt. 12. NOTICE: Only use hand tools when removing the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Remove the RH engine support insulator through bolt. 13. NOTICE: Only use hand tools when removing the engine support insulator nuts or damage to the engine support insulator can occur. NOTE: If during nut removal the stud bolt is extracted from the engine support insulator, separate the nut from the stud bolt prior to stud bolt installation. Remove the 2 RH engine support insulator nuts. 14. NOTICE: Only use hand tools when removing the engine support insulator stud bolts or damage to the engine support insulator can occur. Remove the 2 RH engine support insulator stud bolts. Four-Wheel Drive (4WD) - RH engine support insulator 15. Position a suitable hydraulic jack under the front axle. Securely strap the jack to the axle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2072 16. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows clearance for the isolator bolt. Remove the upper front axle carrier mounting bushing bolt. 17. Remove the axle shaft housing carrier bushing bolt. 18. Remove the lower front axle carrier mounting bushing bolt. 19. NOTICE: Use care when lowering the front axle housing, or when vacuum lines to the axle solenoid may become disconnected or damaged. Lower the axle to allow clearance to the RH lower front mount bracket bolt. RH engine support insulator 20. Using the Engine Support Bar, Support Hook and Engine Support Bracket, raise the engine. 21. Remove the 3 bolts and the RH engine support insulator-to-cylinder block bracket. 22. Remove the RH engine support insulator. LH engine support insulator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2073 23. NOTICE: Only use hand tools when loosening the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Loosen the RH engine support insulator through bolt. 24. NOTICE: Only use hand tools when removing the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Remove the LH engine support insulator through bolt. 25. Using the Engine Support Bar, Support Hook and Engine Support Bracket, raise the engine. 26. NOTICE: Only use hand tools when removing the engine support insulator-to-frame bolts or damage to the engine support insulator-to-frame nut plate can occur. Remove the 3 engine support insulator-to-frame bolts. - Discard the 3 bolts. 27. Remove the 3 bolts and the LH engine support insulator-to-cylinder block bracket. 28. Remove the LH engine support insulator. 29. Inspect the engine support insulator-to-frame nut plate for thread damage. If the nut plate is damaged, bend 2 tabs back and remove the nut plate. Replace the nut plate with service part number 56190 and bend the 2 tabs back to the original position. Installation RH engine support insulator 1. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation. 2. NOTICE: Only use hand tools when installing the engine support insulator stud bolts or damage to the engine support insulator can occur. Position the RH engine support insulator into the vehicle and install the 2 stud bolts. - Tighten to 15 Nm (133 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2074 3. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts. - Tighten to 63 Nm (46 lb-ft). 4. NOTICE: Only use hand tools when installing the RH engine support insulator nuts or damage to the engine support insulator can occur. Install the 2 RH engine support insulator nuts. - Tighten to 175 Nm (129 lb-ft). LH engine support insulator 5. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation. 6. Position the LH engine support insulator and hand start the 3 new engine support insulator-to-frame bolts. - Tighten to 175 Nm (129 lb-ft). 7. Position the LH engine support insulator-to-cylinder block bracket and install the 3 bolts. - Tighten to 63 Nm (46 lb-ft). All engine support insulators 8. Using the Engine Support Bar, Support Hook and Engine Support Bracket, lower the engine into position. 9. NOTICE: Only use hand tools when installing the engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur. Install the LH and RH engine support insulator bolts. - Apply threadlock to the bolt threads prior to installation. - Tighten to 350 Nm (258 lb-ft). 4WD vehicles - RH engine support insulator 10. NOTICE: Use care when positioning the front axle housing or the vacuum lines to the axle solenoid may become disconnected or damaged. Raise the front axle carrier into position. 11. Install the lower front axle carrier mounting bushing bolt. - Tighten to 115 Nm (85 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2075 12. Install the axle shaft housing carrier bushing bolt. - Tighten to 115 Nm (85 lb-ft). 13. Install the upper front axle carrier mounting bushing bolt. - Tighten to 115 Nm (85 lb-ft). All engine support insulators 14. NOTICE: Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur. Install the transmission mount-to-crossmember nuts. - Tighten to 103 Nm (76 lb-ft). 15. Position the Y-pipe and install the 4 nuts (2 RH and 2 LH). - Tighten to 40 Nm (30 lb-ft). 16. Remove the Engine Support Bar, Support Hook and Engine Support Bracket. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 2076 17. Install the starter. 18. If servicing the engine support insulator on a 4WD vehicle, install the front driveshaft. 19. Install the generator. 20. Install the cooling fan. 21. Install the TB. 22. Connect the battery ground cable. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2081 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley Accessory Drive Belt Idler Pulley Removal and Installation 1. Remove the air cleaner outlet pipe. 2. Rotate the accessory drive belt tensioner clockwise and position the accessory drive belt aside. 3. Remove the bolt and the accessory drive belt idler pulley. - To install, tighten to 25 Nm (18 lb-ft). 4. Repeat the previous step for each accessory drive belt idler pulley being serviced. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum oil pressure at idle (engine at normal operating temperature)........................................................................................................172 kPa (25 psi) Oil pressure minimum at 2,000 rpm (engine at normal operating temperature).................................................................................275-517 kPa (40-75 psi) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2086 Engine Oil Pressure: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Engine Lubrication Components - Exploded View Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Engine Lubrication Components Exploded View Engine Lubrication Components - Exploded View 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 2091 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator And Tube Oil Level Indicator and Tube Removal and Installation 1. Remove the LH exhaust manifold. For additional information, refer to Exhaust Manifold - LH See: Exhaust System/Exhaust Manifold/Service and Repair/Removal and Replacement/Exhaust Manifold - LH. 2. Remove the oil level indicator and tube bolt. - To install, tighten to 10 Nm (89 lb-in). 3. Remove the oil level indicator and tube from the cylinder block. - Discard the O-ring seal. 4. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation. To install, reverse the removal procedure. - Install a new O-ring seal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 6.6L (7.0 Qt) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2096 Engine Oil: Fluid Type Specifications Engine Oil U.S.A. ................................................................................................................................... Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada .................................................................................................................................................. Motorcraft SAE 5W-20 Super Premium Motor Oil Ford P/N .............................................................................................................................................. ........................................... XO-5W20-QSP (U.S.A) Ford P/N ............................................................ ...................................................................................................................... CXO-5W20-LSP12 (Canada) Ford Specification ......................................................................................................................................... WSS-M2C930-A with API Certification Mark NOTE: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the requirements of Ford specification WSS-M2C930-A and the API Certification mark. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine cooling system. 3. Drain the engine oil. - Install the drain plug and tighten to 23 Nm (17 lb-ft). 4. Disconnect the engine oil pressure switch electrical connector. 5. Disconnect the lower radiator hose and position it aside. 6. Remove and discard the engine oil filter. - To install, lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact. Using an oil filter strap wrench, tighten the filter an additional 270 degrees. 7. Remove the 4 bolts and the oil filter adapter. - To install, tighten to 25 Nm (18 lb-ft). 8. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2100 cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Remove and discard the oil filter adapter gasket. - Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. - Inspect the mating surfaces. 9. To install, reverse the removal procedure. - Fill the engine with clean engine oil. 10. Fill and bleed the engine cooling system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Position a new gasket and the oil pan and install the 16 bolts. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to................................................................................................ ..........................................................................................2 Nm (18 lb-in). Stage 2: Tighten to........... .............................................................................................................................................................. .............20 Nm (177 lb-in). Stage 3: Tighten an additional................................................................... ..............................................................................................................60 degrees. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2106 Oil Pan: Service and Repair Oil Pan Oil Pan Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished. - Tighten to 23 Nm (17 lb-ft). 3. Remove the 4 nuts, the 4 bolts and the crossmember. Four-Wheel Drive (4WD) vehicles 4. Position a suitable hydraulic jack under the front axle. Securely strap the jack to the axle. 5. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows clearance for the isolator bolt. Remove the upper front axle carrier mounting bushing bolt. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2107 6. Remove the axle shaft housing carrier bushing bolt. 7. Remove the lower front axle carrier mounting bushing bolt. 8. NOTICE: Use care when lowering the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged. Lower the axle to allow clearance for the oil pan to be removed. All vehicles 9. Remove the starter wiring harness rear support bracket bolt. 10. Remove the pushpin, press the position retaining tab and rotate the lower cooling fan shroud upward until the position retainer tab locks into position. 11. Remove the nut and position the starter wiring harness and the transmission fluid cooler tubes aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2108 12. Detach the oil pressure switch wiring harness from the oil pan bolt. 13. Remove the 16 bolts, the oil pan and the gasket. - Discard the gasket. 14. 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 old sealant. Inspect the oil pan. Clean the gasket mating surfaces of the oil pan and engine block with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Installation All vehicles 1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface. 2. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2109 3. Position a new gasket and the oil pan and install the 16 bolts. - Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 2 Nm (18 lb-in). - Stage 2: Tighten to 20 Nm (177 lb-in). - Stage 3: Tighten an additional 60 degrees. 4. Attach the oil pressure switch wiring harness to the oil pan bolt. 5. Position the transmission fluid cooler tube support bracket, the starter wiring harness support bracket and install the nut. - Tighten to 10 Nm (89 lb-in). 6. Press the position retaining tab and rotate the lower cooling fan shroud downward until the position retainer tab locks into position. Install the pushpin. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2110 7. Position the starter wiring harness and install the starter wiring harness rear support bracket bolt. - Tighten to 10 Nm (89 lb-in). 8. Install the transmission fluid cooling tubes rear support bracket bolt. - Tighten to 48 Nm (35 lb-ft). 4WD vehicles 9. NOTICE: Use care when positioning the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged. Raise the front axle carrier into position. 10. Install the lower front axle carrier mounting bushing bolt. - Tighten to 115 Nm (85 lb-ft). 11. Install the axle shaft housing carrier bushing bolt. - Tighten to 115 Nm (85 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2111 12. Install the upper front axle carrier mounting bushing bolt. - Tighten to 115 Nm (85 lb-ft). All vehicles 13. Position the crossmember and install the 4 bolts and the 4 nuts. - Tighten to 90 Nm (66 lb-ft). 14. Fill the engine with clean engine oil. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2115 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2116 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 3. Remove the EOP switch. - To install, tighten to 18 Nm (159 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2121 Oil Pick Up/Strainer: Service and Repair Oil Pump Screen And Pickup Tube Oil Pump Screen and Pickup Tube Removal 1. Remove the oil pan. For additional information, refer to Oil Pan See: Oil Pan/Service and Repair/Oil Pan. 2. Remove the 3 bolts and the oil pump screen and pickup tube. Installation 1. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil prior to installation. Position the oil pump screen and pickup tube and install the 3 bolts. - Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in). - Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft). 2. Install the oil pan. For additional information, refer to Oil Pan See: Oil Pan/Service and Repair/Oil Pan. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum oil pressure at idle (engine at normal operating temperature)........................................................................................................172 kPa (25 psi) Oil pressure minimum at 2,000 rpm (engine at normal operating temperature).................................................................................275-517 kPa (40-75 psi) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2126 Engine Oil Pressure: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Intake Manifold: Specifications Intake Manifold Install the 10 intake manifold bolts and tighten in 2 stages in the sequence shown. Stage 1: Tighten to........................................................................................................................................................... ...............................2 Nm (18 lb-in). Stage 2: Tighten to...................................................................... ..................................................................................................................10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold > Page 2134 Intake Manifold: Specifications Throttle Body Using a new O-ring seal, position the TB, the vibration damper and tighten the 4 bolts in 2 stages. Stage 1: Tighten to............................................................................................................................... ...........................................................9 Nm (80 lb-in). Stage 2: Tighten an additional......................... ............................................................................................................................90 degrees (one-fourth turn). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement Intake Manifold: Removal and Replacement Intake Manifold Air Cleaner (ACL) Outlet Pipe-to-Throttle Body (TB) Adapter and Air Intake Resonator Assembly Throttle Body (TB) and Ignition Coil Electrical Connectors Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2137 Intake Manifold Vacuum Tube Assembly Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2138 Intake Manifold, Coolant Crossover Manifold Assembly and Gaskets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2139 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. 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. Drain the cooling system. 2. Remove the generator. 3. Disconnect the quick connect couplings and remove the crankcase vent tube. 4. Loosen the clamp and remove the bolt and the air intake resonator assembly. 5. Remove the 3 bolts and the Throttle Body (TB)-to-Air Cleaner (ACL) outlet pipe adapter. 6. Disconnect the quick connect couplings and remove the PCV tube. 7. Disconnect the fuel supply tube quick connect coupling. 8. Disconnect the Evaporative Emission (EVAP) electrical connector and the EVAP tube quick connect coupling from the EVAP canister purge valve. 9. Disconnect the upper radiator hose from the thermostat housing. 10. Disconnect the heater coolant hose from the coolant crossover manifold assembly. 11. Disconnect the 8 fuel injector electrical connectors. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2140 12. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors. 13. Disconnect the heated PCV element electrical connector. 14. Disconnect the 4 LH ignition coil and the LH Variable Camshaft Timing (VCT) solenoid electrical connectors and detach the 2 engine wiring harness retainers from the LH valve cover studs. 15. Disconnect the intake manifold vacuum tube from the brake booster vacuum hose. 16. NOTE: The intake manifold vacuum tube must be removed with the intake manifold as an assembly. Disconnect the intake manifold vacuum tube from the LH valve cover studbolt and the support bracket at the rear of the LH cylinder head. 17. Remove the 10 intake manifold bolts. 18. 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 old sealant. Remove the 3 bolts, the coolant crossover manifold assembly and discard the gaskets. - Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 19. NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness and removed with the intake manifold as an assembly. Position the intake forward to gain access to the wiring harness retainers. 20. Disconnect the 2 engine wiring harness retainers from the rear of the intake manifold. 21. Disconnect the Cylinder Head Temperature (CHT) sensor jumper harness electrical connector retainer. 22. 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 old sealant. NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness and removed with the intake manifold as an assembly. Remove the intake manifold and discard the gaskets. - Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Installation 1. 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. NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness during installation of the intake manifold. Using new intake manifold gaskets, position the intake manifold. 2. Position the intake manifold forward and connect the CHT sensor jumper harness electrical connector retainer. 3. Connect the 2 engine wiring harness retainers to the rear of the intake manifold and position back the intake manifold assembly. 4. Using new gaskets, position the coolant crossover manifold assembly and install the 3 bolts. - Tighten to 10 Nm (89 lb-in). 5. Install the 10 intake manifold bolts and tighten in 2 stages in the sequence shown. - Stage 1: Tighten to 2 Nm (18 lb-in). - Stage 2: Tighten to 10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2141 6. Connect the intake manifold vacuum tube to the support bracket and the valve cover stud. 7. Connect the brake booster vacuum hose to the intake manifold vacuum tube. 8. Connect the 4 LH ignition coil and the LH VCT solenoid electrical connectors and attach the 2 engine wiring harness retainers to the LH valve cover studs. 9. Connect the heated PCV element electrical connector. 10. Connect the TP sensor and ETC electrical connectors. 11. Connect the 8 fuel injector electrical connectors. 12. Connect the heater coolant hose to the coolant crossover manifold assembly. 13. Connect the upper radiator hose to the thermostat housing. 14. Connect the EVAP canister purge valve electrical connector and the EVAP tube quick connect coupling to the EVAP canister purge valve. 15. Connect the fuel supply tube quick connect coupling. 16. Position the PCV tube and connect the quick connect couplings. 17. Position the TB-to-ACL outlet pipe adapter and install the 3 bolts. - Tighten to 10 Nm (89 lb-in). 18. Position the air intake resonator assembly, install the bolt and the clamp. - Tighten the bolt to 10 Nm (89 lb-in). 19. Position the crankcase vent tube and connect the quick connect couplings. 20. Install the generator. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2142 21. Fill and bleed the engine cooling system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2143 Intake Manifold: Overhaul Intake Manifold Assembly Evaporative Emission (EVAP) Purge Valve, Fuel Rail and Fuel Injectors Intake Manifold Vacuum Tube, Throttle Body (TB) and Intake Manifold Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2144 Disassembly 1. Remove the bolt and disconnect the quick connect coupling and remove the Evaporative Emission (EVAP) purge valve assembly. 2. Remove the 4 bolts and the fuel rail. 3. Remove the 8 fuel injector-to-fuel rail locking clips and separate the 8 fuel injectors from the fuel rail. - Discard the 2 O-ring seals from each fuel injector. 4. Remove the vacuum tube assembly from the intake manifold. 5. Remove the 2 bolts and the PCV heater element. - Discard the O-ring seal. 6. Remove the 4 bolts, the vibration damper and the Throttle Body (TB). Assembly 1. 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. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 2145 Install the PCV heater element and the 2 bolts. - Tighten to 6 Nm (53 lb-in). 2. Install the vacuum tube assembly onto the intake manifold. 3. Install the TB, vibration damper and tighten the 4 bolts in 2 stages. - Stage 1: Tighten to 9 Nm (80 lb-in). - Stage 2: Tighten an additional 90 degrees. 4. NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation. Install 16 new O-ring seals on each of the fuel injectors. 5. Assemble the 8 fuel injectors onto the fuel rail and install the 8 locking clips. 6. Install the fuel rail and fuel injector as an assembly onto the intake manifold. 7. Install the 4 fuel rail bolts. - Tighten to 10 Nm (89 lb-in). 8. Position the Evaporative Emission (EVAP) purge valve assembly and connect the quick connect coupling and install the bolt. - Tighten to 10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Flexplate Or Flywheel And Crankshaft Rear Seal - Exploded View Crankshaft Main Bearing Seal: Service and Repair Flexplate Or Flywheel And Crankshaft Rear Seal - Exploded View Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Flexplate Or Flywheel And Crankshaft Rear Seal - Exploded View > Page 2151 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal Crankshaft Rear Seal Removal 1. Remove the transmission. 2. Remove the 8 bolts and the flexplate. 3. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Flexplate Or Flywheel And Crankshaft Rear Seal - Exploded View > Page 2152 4. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal. Installation 1. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation. Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal. 2. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation. Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger. 3. Install the flexplate and tighten the 8 bolts in the sequence shown. - Tighten to 80 Nm (59 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Flexplate Or Flywheel And Crankshaft Rear Seal - Exploded View > Page 2153 4. Install the transmission. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Flexplate Or Flywheel And Crankshaft Rear Seal - Exploded View > Page 2154 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal With Retainer Plate Crankshaft Rear Seal with Retainer Plate Removal 1. Remove the transmission. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Flexplate Or Flywheel And Crankshaft Rear Seal - Exploded View > Page 2155 2. Remove the oil pan. For additional information, refer to Oil Pan See: Engine Lubrication/Oil Pan/Service and Repair/Oil Pan. 3. Remove the rear engine cover. 4. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger. 5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal. 6. Remove the 6 bolts and the crankshaft rear seal retainer plate. Installation 1. 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 old sealant. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Clean and inspect the mating surface. 2. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leaks. NOTE: The silicone must be applied on the groove along the retainer plate. Apply a 4.06 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer plate sealing surface. 3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown. - Tighten to 10 Nm (89 lb-in). 4. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Flexplate Or Flywheel And Crankshaft Rear Seal - Exploded View > Page 2156 Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal. 5. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation. Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger. 6. Install the rear engine cover. 7. Install the flexplate and tighten the 8 bolts in the sequence shown. - Tighten to 80 Nm (59 lb-ft). 8. Install the oil pan. For additional information, refer to Oil Pan See: Engine Lubrication/Oil Pan/Service and Repair/Oil Pan. 9. Install the transmission. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2160 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the cooling fan. 3. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley. 4. Remove the crankshaft pulley bolt and washer. - Discard the crankshaft pulley bolt. 5. Using the 3-Jaw Puller, remove the crankshaft pulley. 6. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft seal. Installation 1. Lubricate the engine front cover and the new crankshaft seal inner lip with clean engine oil. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2161 2. Using the Crankshaft Front Oil Seal Installer, the Crankshaft Vibration Damper Installer and the Front Cover Oil Seal Installer, install the new crankshaft front seal into the engine front cover. 3. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley. 4. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley. 5. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. - Stage 1: Tighten to 90 Nm (66 lb-ft). - Stage 2: Loosen 360 degrees. - Stage 3: Tighten to 50 Nm (37 lb-ft). - Stage 4: Tighten an additional 90 degrees. 6. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2162 7. Install the cooling fan. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2167 Valve Guide Seal: Service and Repair Valve Seals Valve Seals Removal RH cylinder head valve seals 1. Remove the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. LH cylinder head valve seals 2. Remove the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. All valve seals 3. Remove the spark plug for the cylinder being serviced. 4. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed. 5. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2168 6. Use compressed air in the cylinder being serviced to hold the valves in position. - Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder. 7. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: 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. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys. 8. Remove the valve spring retainer, the valve spring and the valve seal. - Discard the valve seal. 9. Inspect the components. Installation All valve seals 1. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation. Position a new valve seal onto the valve stem. 2. Using the Valve Stem Oil Seal Installer, install the new valve seal. 3. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow this instruction may result in engine damage. Using the Valve Spring Compressor, install the valve spring, the valve spring retainer and the valve spring retainer keys. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2169 4. Relieve the air pressure from the cylinder. 5. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow this instruction may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower. 6. Install the spark plug. LH cylinder head valve seals 7. Install the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. RH cylinder head valve seals 8. Install the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2174 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2175 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 3. Remove the EOP switch. - To install, tighten to 18 Nm (159 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages. Stage 1: Tighten to................................................................................................................ .........................................................................40 Nm (30 lb-ft). Stage 2: Tighten an additional.......... .............................................................................................................................................................. .........90 degrees. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams Timing Chain: Diagrams NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons may result. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks. Install the crankshaft sprocket, making sure the flange faces forward. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the camshaft phaser and sprocket with the timing mark positioned between the 2 copper (marked) chain links. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 2186 Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is positioned between the 2 copper (marked) chain links. As a post-check, verify correct alignment of all timing marks. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Position the LH and RH timing chain guides and install the 4 bolts. Tighten to................................... .............................................................................................................................................................. .....10 Nm (89 lb-in). Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts. Tighten to.......................................................................................................... .............................................................................................25 Nm (18 lb-ft). Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts. Tighten to.................................................................................................... ...................................................................................................25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2190 Timing Chain Tensioner: Service and Repair Timing Drive Components Removal 1. Remove the engine front cover. For additional information, refer to Engine Front Cover See: Timing Cover/Service and Repair. 2. Remove the crankshaft sensor ring from the crankshaft. 3. Position the crankshaft keyway at the 12 o'clock position. 4. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2191 The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder. 5. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head. 6. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head. 7. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2192 8. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove the 3 designated camshaft roller followers in the previous step from the LH cylinder head. 9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position. 10. NOTICE: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2193 11. NOTICE: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm. 12. Remove the RH and LH timing chains and the crankshaft sprocket. - Remove the RH timing chain from the camshaft sprocket. - Remove the RH timing chain from the crankshaft sprocket. - Remove the LH timing chain from the camshaft sprocket. - Remove the LH timing chain and crankshaft sprocket. 13. NOTE: RH shown, LH similar. Remove the LH and RH timing chain guides. - Remove the 4 bolts. - Remove both timing chain guides. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2194 14. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Using the Cam Phaser Locking Tool, remove the bolt and the RH camshaft phaser and sprocket assembly. - Discard the camshaft phaser and sprocket bolt. 15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser and sprocket assembly. - Discard the camshaft phaser and sprocket bolt. 16. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Remove the 2 bolts and the RH camshaft front bearing cap. 17. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining bolts in the sequence shown and remove the remaining RH camshaft bearing caps. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2195 18. Clean and inspect the RH camshaft bearing caps. - The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. 19. Remove the RH camshaft. 20. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Remove the 2 bolts and the RH camshaft front bearing cap. 21. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining bolts in the sequence shown and remove the remaining LH camshaft bearing caps. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2196 22. Clean and inspect the LH camshaft bearing caps. - The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. 23. Remove the LH camshaft. 24. NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage. Remove all of the remaining camshaft roller followers from the cylinder heads. Installation 1. Install the LH and RH camshafts. - Lubricate the camshaft and camshaft journals with clean engine oil prior to installation. 2. NOTE: LH shown, RH similar. Install the LH and RH camshaft bearing caps in their original locations. - Lubricate the camshaft bearing caps with clean engine oil. - Position the 2 front camshaft bearing caps. - Position the 8 remaining camshaft bearing caps. - Install the 20 bolts loosely. - Tighten to 10 Nm (89 lb-in) in the sequence shown. 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: LH shown, RH similar. Position the camshaft phaser and sprockets and install 2 new camshaft phaser and sprocket bolts finger-tight. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2197 4. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: LH shown, RH similar. Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). - Stage 2: Tighten an additional 90 degrees. 5. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool. 6. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result. NOTICE: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur. Compress the tensioner plunger, using a vise. 7. Install a retaining clip on the tensioner to hold the plunger in during installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2198 8. Remove the tensioner from the vise. 9. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks. 10. Install the crankshaft sprocket, making sure the flange faces forward. 11. Install the 4 bolts and the LH and RH timing chain guides. - Tighten to 10 Nm (89 lb-in). 12. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain. 13. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the camshaft phaser and sprocket with the timing mark positioned between the 2 copper (marked) chain links. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2199 14. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the 2 bolts. - Tighten to 25 Nm (18 lb-ft). 15. Remove the retaining clip from the LH timing chain tensioner. 16. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link. 17. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft. Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is positioned between the 2 copper (marked) chain links. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2200 18. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts. - Tighten to 25 Nm (18 lb-ft). 19. Remove the retaining clip from the RH timing chain tensioner. 20. As a post-check, verify correct alignment of all timing marks. 21. Install the crankshaft sensor ring on the crankshaft. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2201 22. NOTICE: If the components are to be reinstalled, they must be installed into their original locations. Failure to follow this instruction may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install all of the camshaft roller followers. Lubricate the camshaft roller followers with clean engine oil prior to installation. 23. Install the engine front cover. For additional information, refer to Engine Front Cover See: Timing Cover/Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Tighten the 15 engine front cover fasteners in the sequence shown in 2 stages. Stage 1: Tighten fasteners 1 through 15 to.....................................................................................................................................................25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to............................................................................ .................................................................................48 Nm (35 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2205 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2206 Timing Cover: Service and Repair Engine Front Cover Front End Accessory Drive (FEAD), LH and RH Camshaft Position (CMP) Sensors Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2207 Radio Ignition Interference Capacitors, Coolant Pump Pulley, Crankshaft Pulley and Front Oil Pan Bolts Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2208 Engine Front Cover, Gaskets and Crankshaft Position (CKP) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2209 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. 3. Remove the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. 4. Remove the engine cooling fan. 5. Loosen the 4 coolant pump pulley bolts. 6. Rotate the tensioner clockwise and remove the accessory drive belt. 7. Remove the 4 bolts and the coolant pump pulley. 8. Drain the engine oil. 9. Remove the pushpin and press the position retaining tab and rotate the lower cooling fan shroud upward until the position retainer tab locks into position. 10. Remove the bolt and position the starter wiring harness and starter wiring harness rear support bracket aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2210 11. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring harness support bracket. 12. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 13. Remove the nut and position aside the power steering pressure hose support bracket. 14. Remove the crankshaft pulley bolt and washer. - Discard the crankshaft pulley bolt. 15. Remove and discard the crankshaft pulley bolt. Using the 3-Jaw Puller, remove the crankshaft pulley. 16. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal. 17. Remove the 3 bolts and the 3 accessory drive idler pulleys. 18. Remove the 3 bolts and the accessory drive belt tensioner. 19. If equipped, remove the 4 bolts and the skid plate. 20. Remove the 4 front oil pan bolts. 21. Disconnect the wiring harness retainer from the power steering pump studbolt. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2211 22. Remove the stud bolt, the 2 bolts, and position aside the power steering pump. 23. Disconnect the RH Camshaft Position (CMP) sensor electrical connector. 24. Remove the bolt and the RH CMP sensor. 25. Remove the nut and position the RH radio ignition interference capacitor aside. 26. Disconnect the LH CMP sensor electrical connector. 27. Remove the bolt and the LH CMP sensor. 28. Remove the nut and position the LH radio ignition interference capacitor aside. 29. Remove the 10 bolts and the 5 studs. 30. Remove the engine front cover from the front cover-to-cylinder block dowel. - Remove the engine front cover gaskets. 31. Remove the bolt and the CKP sensor. - Discard the O-ring seal. 32. 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 old sealant. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. - Inspect the mating surfaces. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2212 1. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the CKP sensor and the bolt. - Tighten to 10 Nm (89 lb-in). 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 old sealant. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown. 3. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight. 4. Tighten the 15 engine front cover fasteners in the sequence shown in 2 stages. - Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft). - Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2213 5. Loosely install the 4 bolts, then tighten in 2 stages, in the sequence shown. - Stage 1: Tighten to 20 Nm (177 lb-in). - Stage 2: Tighten an additional 60 degrees. 6. Connect the CKP sensor electrical connector. 7. Position the starter wiring harness support bracket and the transmission cooler tube support bracket and tighten the nut. - Tighten to 10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2214 8. Position the starter wiring harness and starter wiring harness rear support bracket and install the bolt. - Tighten to 10 Nm (89 lb-in). 9. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil. 10. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and the Crankshaft Front Oil Seal Installer, install a new crankshaft front seal into the engine front cover. 11. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. 12. Use the Crankshaft Vibration Damper Installer to install the crankshaft pulley. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2215 13. Tighten the new crankshaft pulley bolt in 4 stages. - Stage 1: Tighten to 90 Nm (66 lb-ft). - Stage 2: Loosen 360 degrees. - Stage 3: Tighten to 50 Nm (37 lb-ft). - Stage 4: Tighten an additional 90 degrees. 14. Install the accessory drive belt tensioner and the 3 bolts. - Tighten to 25 Nm (18 lb-ft). 15. Install the 3 accessory drive idler pulleys and the 3 bolts. - Tighten to 25 Nm (18 lb-ft). 16. Position the coolant pump pulley and install the 4 bolts finger-tight. 17. Rotate the lower cooling fan shroud downward until the position retainer tab locks into position and install the pushpin. 18. If equipped, install the skid plate and the 4 bolts. - Tighten to 25 Nm (18 lb-ft). 19. Position the power steering pump and install the stud bolt and the 2 bolts. - Tighten to 25 Nm (18 lb-ft). 20. Attach the engine wiring harness to the power steering pump stud bolt. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2216 21. Position the power steering pressure hose support bracket and install the nut. - Tighten to 10 Nm (89 lb-in). 22. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the RH CMP sensor and the bolt. - Tighten to 10 Nm (89 lb-in). 23. Connect the RH CMP sensor electrical connector. 24. Install the LH radio ignition interference capacitor and the nut. - Tighten to 25 Nm (18 lb-ft). 25. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the LH CMP sensor and the bolt. - Tighten to 10 Nm (89 lb-in). 26. Connect the LH CMP sensor electrical connector. 27. Install the RH radio ignition interference capacitor and the nut. - Tighten to 25 Nm (18 lb-ft). 28. Rotate the tensioner clockwise and install the accessory drive belt. 29. Tighten the 4 coolant pump pulley bolts. - Tighten to 25 Nm (18 lb-ft). 30. Install the engine cooling fan. 31. Install the LH valve cover. For additional information, refer to Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. 32. Install the RH valve cover. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH. 33. Fill the crankcase with clean engine oil. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2217 34. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise Variable Valve Timing Actuator: Customer Interest Engine - Low Frequency Hot Idle Knocking Noise TSB 10-18-4 09/27/10 LOW FREQUENCY ENGINE KNOCKING NOISE AT HOT IDLE FORD: 2009-2010 Expedition, F-150, F-250, F-350 LINCOLN: 2009-2010 Navigator This article supersedes TSB 09-23-7 to update the vehicle model lines, Service Procedure and Service Labor Time Standards. ISSUE Some 2009-2010 F-150 and F-Super Duty vehicles equipped with a 4.6L 3V or 5.4L 3V engine, Expedition and Navigator vehicles may exhibit a low frequency knocking noise from the engine at hot idle only. The noise is predominately heard from the right front wheel well area and/or the right hand (RH) engine cam cover. This noise may be generated from the RH variable camshaft timing (VCT) phaser assembly. This procedure was created to diagnose the RH VCT phaser assembly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The Integrated Diagnostic System (IDS) tests were developed specifically for the vehicles and Power Control Module (PCM) strategies for these vehicles. Per Workshop Manual (WSM), Powertrain Controls and Emissions Diagnostics (PC/ED) and Scheduled Maintenance Guide, review customer service history for use of any aftermarket oil filters. 1. Check for possible diagnostic trouble codes (DTCs). a. No DTCs present, proceed to Step 2. b. If DTCs are present, do not continue with this procedure and refer to the PC/ED manual for diagnostics. 2. Engine must be at full operating temperature over 190 °F (88 °C) cylinder head temperature (CHT). 3. Connect IDS diagnostics tool and verify software version is at the latest level (63 or later required). 4. Begin a new vehicle session. 5. Open Tool Box selection. 6. Open Data Logger. 7. Select Powertrain Engine. 8. Select PCM Data Logger. 9. Clear the preselected items by clicking the eraser icon button. 10. Select variable cam timing desired angle number (VCLDSD). 11. Go to live display and press the tick mark. 12. Make sure the parameter identification (PID) is highlighted with the dark lines above and below the data being displayed. 13. Press number symbol: (output state control mode) of the VCT_DSD number PID. 14. Press the Control Item Activate (finger on the button) icon to enable manual control of the PID. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise > Page 2227 15. Use the plus button to command to 4 degrees. (One click is equal to 1 degree) When commanding the advance, both banks will normally adjust. 16. Listen carefully to the low frequency knock noise while commanding the VCT_DSD from 0 to 4 degrees. Some higher frequency clatter is normal at or above the 5 degree advance. What is being pursued is for the level of the low frequency knock noise to be noticeably reduced when advanced from 4 to 5 degrees. a. If noise level is noticeably reduced as the VCT desired angle is commanded from 3 to 4 degrees, the noise source is the RH VCT phaser assembly. Proceed to Step 17. b. If the low frequency knock noise is not noticeably reduced at 4 degrees, refer to WSM, Section 303-00 for engine noise diagnostics. 17. Due to normal engine dynamics, the VCT phaser knock noise is produced by the RH VCT phaser assembly. Replace only the RH VCT phaser assembly. Refer to WSM, Section 303-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT:Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101804A 2009-2010 Expedition, 2.3 Hrs Navigator 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150 4.6L 3V: 1.8 Hrs. Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150, F-Super 2.1 Hrs. Duty 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6A257 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Low Frequency Hot Idle Knocking Noise TSB 10-18-4 09/27/10 LOW FREQUENCY ENGINE KNOCKING NOISE AT HOT IDLE FORD: 2009-2010 Expedition, F-150, F-250, F-350 LINCOLN: 2009-2010 Navigator This article supersedes TSB 09-23-7 to update the vehicle model lines, Service Procedure and Service Labor Time Standards. ISSUE Some 2009-2010 F-150 and F-Super Duty vehicles equipped with a 4.6L 3V or 5.4L 3V engine, Expedition and Navigator vehicles may exhibit a low frequency knocking noise from the engine at hot idle only. The noise is predominately heard from the right front wheel well area and/or the right hand (RH) engine cam cover. This noise may be generated from the RH variable camshaft timing (VCT) phaser assembly. This procedure was created to diagnose the RH VCT phaser assembly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The Integrated Diagnostic System (IDS) tests were developed specifically for the vehicles and Power Control Module (PCM) strategies for these vehicles. Per Workshop Manual (WSM), Powertrain Controls and Emissions Diagnostics (PC/ED) and Scheduled Maintenance Guide, review customer service history for use of any aftermarket oil filters. 1. Check for possible diagnostic trouble codes (DTCs). a. No DTCs present, proceed to Step 2. b. If DTCs are present, do not continue with this procedure and refer to the PC/ED manual for diagnostics. 2. Engine must be at full operating temperature over 190 °F (88 °C) cylinder head temperature (CHT). 3. Connect IDS diagnostics tool and verify software version is at the latest level (63 or later required). 4. Begin a new vehicle session. 5. Open Tool Box selection. 6. Open Data Logger. 7. Select Powertrain Engine. 8. Select PCM Data Logger. 9. Clear the preselected items by clicking the eraser icon button. 10. Select variable cam timing desired angle number (VCLDSD). 11. Go to live display and press the tick mark. 12. Make sure the parameter identification (PID) is highlighted with the dark lines above and below the data being displayed. 13. Press number symbol: (output state control mode) of the VCT_DSD number PID. 14. Press the Control Item Activate (finger on the button) icon to enable manual control of the PID. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise > Page 2233 15. Use the plus button to command to 4 degrees. (One click is equal to 1 degree) When commanding the advance, both banks will normally adjust. 16. Listen carefully to the low frequency knock noise while commanding the VCT_DSD from 0 to 4 degrees. Some higher frequency clatter is normal at or above the 5 degree advance. What is being pursued is for the level of the low frequency knock noise to be noticeably reduced when advanced from 4 to 5 degrees. a. If noise level is noticeably reduced as the VCT desired angle is commanded from 3 to 4 degrees, the noise source is the RH VCT phaser assembly. Proceed to Step 17. b. If the low frequency knock noise is not noticeably reduced at 4 degrees, refer to WSM, Section 303-00 for engine noise diagnostics. 17. Due to normal engine dynamics, the VCT phaser knock noise is produced by the RH VCT phaser assembly. Replace only the RH VCT phaser assembly. Refer to WSM, Section 303-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT:Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101804A 2009-2010 Expedition, 2.3 Hrs Navigator 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150 4.6L 3V: 1.8 Hrs. Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150, F-Super 2.1 Hrs. Duty 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6A257 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 2234 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 2235 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Cover / Housing > Component Information > Service and Repair > Procedures Variable Valve Timing Cover / Housing: Procedures 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Cover / Housing > Component Information > Service and Repair > Procedures > Page 2240 Variable Valve Timing Cover / Housing: Removal and Replacement Variable Camshaft Timing (VCT) Housing Removal All Variable Camshaft Timing (VCT) housings 1. Remove the timing drive components. For additional information, refer to Timing Drive Components See: Service and Repair/Removal and Replacement. RH VCT housing 2. Remove the 2 bolts and the RH Variable Camshaft Timing (VCT) housing. LH VCT housing 3. Remove the 2 bolts and the LH VCT housing. All VCT housings 4. Remove and discard the VCT housing gasket. 5. 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 old sealant. Clean and inspect the cylinder head sealing surfaces with metal surface prep. Follow the directions on the packaging. 6. Clean and inspect the VCT housing. Installation All VCT housing Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Cover / Housing > Component Information > Service and Repair > Procedures > Page 2241 1. Install a new gasket onto the VCT housing. RH VCT housing 2. Position the RH VCT housing and install the 2 bolts. - Tighten to 10 Nm (89 lb-in). LH VCT housing 3. Position the LH VCT housing and install the 2 bolts. - Tighten to 10 Nm (89 lb-in). All VCT housings 4. Install the timing drive components. For additional information, refer to Timing Drive Components See: Service and Repair/Removal and Replacement. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Variable Camshaft Timing (VCT) Solenoid 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Variable Camshaft Timing (VCT) Solenoid 1 > Page 2246 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Variable Camshaft Timing (VCT) Solenoid 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Variable Camshaft Timing (VCT) Solenoid 1 > Page 2249 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Page 2250 Variable Valve Timing Solenoid: Service and Repair Variable Camshaft Timing (VCT) Oil Control Solenoid NOTE: LH shown, RH similar. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Engine running..................................................................................................................................... ..............................................379-414 kPa (55-60 psi) Key ON Engine OFF (KOEO)......................... ..................................................................................................................................379-414 kPa (55-60 psi) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2255 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. Remove the cap from the fuel pressure relief valve located on the fuel rail. 2. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 3. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 4. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place 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. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2256 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 695 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2265 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element Removal and Installation 1. Disconnect the Air Cleaner (ACL) outlet pipe from the ACL cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Release the retaining clips and position the ACL cover aside. 4. Remove the ACL element. 5. NOTE: The ACL element must be fully seated into the ACL housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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: 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. 1. Disconnect the battery ground cable. 2. Remove the cap from the fuel pressure relief valve located on the fuel rail. 3. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 4. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the Fuel Pressure Test Kit and relieve the fuel pressure. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Page 2270 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order Firing Order: Specifications Firing Order Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order > Page 2275 Firing Order: Specifications Engine Cylinder Identification Engine Cylinder Identification Ford Expedition 2wd Workshop Manual (V8-5.4L (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° Before Top Dead Center (BTDC) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Spark plug gap..................................................................................................................................... .................................1.05 ± 0.05 mm (0.039-0.043 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2283 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................12 Nm (106 lb-in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2284 Spark Plug: Application and ID Spark plug............................................................................................................................................ ...................................................................HJFS-24FP Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2285 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2286 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Engine Ignition - RH Engine Ignition - LH 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2289 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal NOTICE: The spark plug procedure must be followed exactly or damage to the cylinder head and spark plug will result. 1. Remove the ignition coil-on-plug. For additional information, refer to Ignition Coil-On-Plug See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plug. 3. Inspect the spark plug. Installation 1. Adjust the spark plug gap as necessary. For the correct spark plug gap specification, refer to Specifications. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Install the spark plug. - To install, tighten to 12 Nm (106 lb-in). 3. Install the ignition coil. For additional information, refer to Ignition Coil-On-Plug See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2293 Compression Check: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2294 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Tighten the 4 coolant pump bolts. Tighten to....................................................................................... ................................................................................................................25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2298 Water Pump: Service and Repair Coolant Pump Removal 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair/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. Loosen the 4 coolant pump pulley bolts. 4. Remove the accessory drive belt. 5. Remove the 4 bolts and the coolant pump pulley. 6. Remove the 4 bolts and the coolant pump. Discard the O-ring seal. 7. Inspect the sealing surfaces and clean with metal surface prep. Follow the directions on the packaging. Installation 1. NOTICE: Align the bolt holes with the bosses prior to insertion of the coolant pump and insert the pump straight into the coolant pump cavity. Do not rotate the coolant pump once installed in the coolant pump cavity or damage to the O-ring seal can occur, causing the coolant pump to leak. NOTE: Install a new O-ring seal and lubricate with clean engine coolant. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2299 Install the coolant pump and 4 bolts. - Tighten to 25 Nm (18 lb-ft). 2. Install the coolant pump pulley and 4 bolts. 3. Install the accessory drive belt. 4. Tighten the 4 bolts for the coolant pump pulley. - Tighten to 25 Nm (18 lb-ft). 5. Install the cooling fan. For additional information, refer to Cooling Fan See: Cooling System/Radiator Cooling Fan/Fan Blade/Service and Repair. 6. Fill the engine cooling system. For addition information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair/Cooling System Draining, Filling And Bleeding. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant BASE RADIATOR Without aux rear heat .......................................................................................................................... ........................................ 16.4 quarts (15.5 liters) With aux rear heat ................................................ ....................................................................................................................... 19.0 quarts (18.0 liters) HEAVY DUTY TRAILER TOW RADIATOR Without aux rear heat .......................................................................................................................... ........................................ 16.9 quarts (16.0 liters) With aux rear heat ................................................ ....................................................................................................................... 19.5 quarts (18.5 liters) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2305 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant (yellow-colored) Ford P/N .............................................................................................................................................. .................................................................. VC-7-B Ford Specification ................................................ ................................................................................................................................ WSS-M97B51-A1 Add the coolant type originally equipped in your vehicle. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Removal and Installation 1. The coolant crossover manifold assembly is serviced with the intake manifold. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Coolant Expansion Tank Removal and Installation 1. 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. Using a suitable suction device, siphon the coolant from the coolant expansion tank. 2. Remove the Air Cleaner (ACL) element. 3. Remove the hood sensor and nut. 4. Disconnect the coolant overflow hose from the radiator. 5. Remove the 2 bolts and the coolant expansion tank/lower ACL housing assembly. - To install, tighten to 15 Nm (133 lb-in). 6. To install, reverse the removal procedure. - Fill the coolant expansion tank with a 50/50 mixture of coolant and clean, drinkable water. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in 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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2323 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2324 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 Radiator Cooling Fan Motor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2333 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2334 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the cooling fan electronic clutch electrical connector. 3. Remove the nut and the cooling fan electronic clutch harness support bracket from the stud bolt. - To install, tighten to 13 Nm (115 lb-in). 4. Remove the 2 cooling fan shroud pushpins. - Discard the pushpins. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2341 5. Release the cooling fan shroud position tab and rotate the shroud upwards until the lower tab locks into position. 6. NOTICE: Do not sideload the cooling fan clutch coil or the cooling fan clutch may be damaged. Using the Fan Clutch Nut Wrench and Fan Pulley Holding Wrench, remove the cooling fan and clutch assembly. - To install, tighten to 48 Nm (35 lb-ft). - If servicing the cooling fan or cooling fan clutch, refer to Cooling Fan and Cooling Fan Clutch See: Service and Repair. 7. To install, reverse the removal procedure. - Install 2 new cooling fan shroud pushpins. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2345 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2346 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2354 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2355 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2356 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor and discard. - To install, tighten to 10 Nm (89 lb-in). - Coat the new CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Cooling Module, Power Steering Fluid Reservoir, Hoses and Power Distribution Box (PDB) Cooling Fan Shroud Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2360 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Cooling System Draining, Filling And Bleeding. 4. Remove the upper air deflector. 1. Remove the 12 upper air deflector pushpin-type retainers. 2. Remove the air deflector. 5. Remove the Air Cleaner (ACL) outlet pipe. 6. Remove the nut and disconnect the electrical cables. - To install, tighten to 10 Nm (89 lb-in). 7. Disconnect the wiring harness retainer. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2361 8. Disconnect the upper radiator hose from the radiator. 9. Disconnect the upper radiator hose position retainer from the cooling fan shroud. 10. Disconnect the electrical connector and the wiring harness position retainer. 11. If equipped, disconnect the wiring harness position retainer from the vacuum reservoir. 12. If equipped, disconnect the vacuum connectors and the electrical connector on the LH side of the cooling fan shroud and remove the vacuum canister. 13. Disconnect the wiring harness retainer from the RH side of the radiator. 14. NOTE: LH shown, RH similar. Remove the 2 cooling fan shroud bolts and the wiring harness retainers. - To install, tighten to 7 Nm (62 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2362 15. Remove the 4 bolts and position the Power Distribution Box (PDB) and support bracket aside. - NOTICE: Hand start the 4 Power Distribution Box (PDB) support bracket bolts or damage to the radiator support can result. To install, tighten to 10 Nm (89 lb-in). 16. Disconnect the Mass Air Flow (MAF) sensor electrical harness position retainer. 17. Disconnect the power steering fluid hose position retainer from the radiator support. 18. Remove the bolt and position the power steering reservoir aside. - To install, tighten to 11 Nm (97 lb-in). 19. Disconnect the coolant overflow hose from the radiator. 20. Remove the 2 lower cooling fan shroud pushpin retainers. - Discard the retainers. 21. Release the lower cooling fan shroud position tab and rotate the lower cooling fan shroud upwards until the lower tab locks into position. 22. Remove the clip and disconnect the lower radiator hose quick connect coupling from the radiator. 23. Remove the cooling fan shroud. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2363 24. To install, reverse the removal procedure. - Install 2 new lower cooling fans shroud pushpin retainers. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 following 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: Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in the heater 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-specified clamps can cause leakage at the heater hose connection and damage the heater core. Check the integrity of the heater hose clamps. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 2368 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 hoses to see if they are hot. 4. If the outlet only is not hot: - the heater core may have an air pocket. - the heater core may be plugged. 5. If the inlet only is not hot: - the thermostat may not be working correctly. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 2369 Heater Core: Testing and Inspection Heater Core - Pressure Test Climate Control System Component Tests Heater Core - Pressure Test WARNING: Before disconnecting any heater water hoses, shut OFF the engine and wait until engine is fully cool. Failure to comply with this warning may result in serious injury or burns from hot liquid escaping from the engine cooling system. Use the Pressure Test Kit to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Drain the coolant from the cooling system. 2. Disconnect the heater 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 hoses with water and install the plug BT-7422-B and the adapter BT-7422-A from the Pressure Test Kit. Secure the heater 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 hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle and carry out the bench test. See: Heater Core - Bench Test Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 2370 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 hoses with plug and adapter to the core tubes. Then connect 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, install a new heater core. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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 8 plenum chamber screws. 3. Release the plenum chamber clip and position the plenum chamber aside. 4. Remove 2 heater core fitting clips and the dash panel seal. 5. Remove the heater core tube bracket screw and the heater core tube bracket. 6. Remove the heater core bracket screw and the heater core bracket. 7. Remove the heater core. 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2373 Heater Core: Service and Repair Auxiliary Heater Core Auxiliary Heater Core - Expedition, Navigator 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 auxiliary heater core and evaporator core housing. For additional information, refer to Auxiliary Heater Core and Evaporator Core Housing - Expedition, Navigator See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Auxiliary Heater Core and Evaporator Core Housing. 2. Release the clip and open the floorpan bracket. 3. Remove the heater core tube bracket screw and the heater core tube bracket. 4. Remove the 12 evaporator/heater core access cover screws. 5. Remove the evaporator/heater core access cover. 6. Remove the heater core. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2374 Heater Core: Service and Repair Auxiliary Heater Core - Expedition EL, Navigator L Auxiliary Heater Core - Expedition EL, Navigator L 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. NOTE: It is not necessary to install the new heater core tubes contained in the heater core service kit unless there is evidence of damage to the heater core tubes. New O-ring seals must be installed any time the heater core tubes are detached from the heater core. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the RH quarter trim panel. 4. Position a suitable drain pan and disconnect the 2 auxiliary heater outlet and inlet line quick disconnect fittings at the floorpan connections to allow any residual coolant to drain from the auxiliary heater core. 5. Remove the heater core door screw. 6. Remove the 2 auxiliary heater core tube fitting clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2375 7. Disconnect the 2 auxiliary heater core tubes. 1. Position the auxiliary heater core partially out of the housing. 2. Disconnect the auxiliary heater core inlet tube. 3. Disconnect the auxiliary heater core outlet tube. - Discard the O-ring seals. 8. Remove the auxiliary heater core. 9. NOTE: Use only the O-ring seals contained in the auxiliary heater core service kit. NOTE: Verify that the heater core tube fittings are completely seated in the heater core before installing the heater core tube fitting clips. To install, reverse the removal procedure. 10. Fill the engine cooling system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module Radiator: Service and Repair Cooling Module Cooling Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2380 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Cooling System Draining, Filling And Bleeding. 3. Recover the A/C system refrigerant. 4. Disconnect the battery ground cable. 5. Remove the RH and LH headlamp assemblies. 6. Remove the front bumper cover. 7. Release the 2 clamps and disconnect the 2 power steering fluid cooler hoses from the condenser core. 8. Remove the cooling fan shroud. For additional information, refer to Cooling Fan Shroud See: Fan Shroud/Service and Repair. 9. Remove the 2 hood latch assembly bolts. 10. Disconnect the 2 cable position retainers and position the hood latch assembly aside. 11. Remove the pushpin and move the air deflector aside. 12. Remove the 2 transmission cooler tube secondary latches. 13. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler hoses. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2381 14. Remove the condenser inlet fitting bolt, the condenser outlet fitting nut and disconnect the 2 fittings. - Discard the O-ring seals. 15. Disconnect the horn assembly electrical connector. 16. Disconnect the ambient temperature sensor electrical connector. 17. Remove the 6 cooling module bolts and remove the cooling module from the vehicle. Installation 1. Position the cooling module in the vehicle. 2. Install the 6 cooling module bolts. - Tighten to 25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2382 3. Connect the ambient temperature sensor electrical connector. 4. Connect the horn assembly electrical connector. 5. Using new O-ring seals, connect the A/C condenser outlet and inlet fittings and install the nut and bolt. - Tighten to 15 Nm (133 lb-in). 6. Connect the transmission fluid cooler tubes and install the 2 secondary latches. 7. Position the air deflector and install the pushpin. 8. Position the hood latch assembly and install the 2 hood latch assembly bolts. - Tighten to 25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2383 9. Connect the 2 hood latch cable position retainers. 10. Install the cooling fan shroud. For additional information, refer to Cooling Fan Shroud See: Fan Shroud/Service and Repair. 11. Connect the 2 power steering fluid cooler hoses to the condenser core. 12. Install the front bumper cover. 13. Install the RH and LH headlamp assemblies. 14. Connect the battery ground cable. 15. Fill and bleed the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Cooling System Draining, Filling And Bleeding. 16. Fill and bleed the power steering system. 17. Fill the transmission with fluid and verify correct operation. 18. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2384 Radiator: Service and Repair Radiator Radiator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH and LH headlamp assemblies. 3. Remove the cooling fan shroud. For additional information, refer to Cooling Fan Shroud See: Fan Shroud/Service and Repair. 4. Remove the 2 radiator bolts. - To install, tighten to 15 Nm (133 lb-in). 5. Remove the 2 bolts and position the coolant expansion tank aside. - To install, tighten to 15 Nm (133 lb-in). 6. Disconnect the electrical connector and remove the bolt and the horn assembly. - To install, tighten to 10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Cooling Module > Page 2385 7. NOTE: LH shown, RH similar. Remove the 6 LH and RH air deflector-to-condenser core pin-type retainers. 8. Disconnect the 2 transmission fluid cooler-to-radiator hoses. 9. NOTE: The cooling module must be positioned rearward to raise and detach the 4 condenser mounts from the radiator. Depress the retaining tabs on the 2 lower condenser mounting brackets and raise the condenser assembly until the 4 condenser mounting brackets detach from the radiator. 10. Remove the radiator. 11. To install, reverse the removal procedure. - Fill the transmission fluid level. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2397 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy. Typical CHT Sensor Typical CHT Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2399 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor and discard. - To install, tighten to 10 Nm (89 lb-in). - Coat the new CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature Starts to open....................................................................................................................................... .............................................86.7-90.6°C (188-195°F) Fully open....................................................... ...................................................................................................................................................100°C (212°F) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2403 Thermostat: Service and Repair Thermostat and Thermostat Housing Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Cooling System Draining, Filling And Bleeding. 2. If servicing the thermostat housing, disconnect the upper radiator hose from the thermostat housing. 3. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal. - Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep and silicone gasket remover. Follow the directions on the packaging. - If necessary, install a new thermostat with the spring facing down. - Install a new O-ring seal. - NOTE: Make sure the thermostat housing is seated evenly by hand tightening the 2 thermostat housing bolts prior to final tightening. To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Thermostat and Thermostat Housing Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Cooling System Draining, Filling And Bleeding. 2. If servicing the thermostat housing, disconnect the upper radiator hose from the thermostat housing. 3. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal. - Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep and silicone gasket remover. Follow the directions on the packaging. - If necessary, install a new thermostat with the spring facing down. - Install a new O-ring seal. - NOTE: Make sure the thermostat housing is seated evenly by hand tightening the 2 thermostat housing bolts prior to final tightening. To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Tighten the 4 coolant pump bolts. Tighten to....................................................................................... ................................................................................................................25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2410 Water Pump: Service and Repair Coolant Pump Removal 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/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. Loosen the 4 coolant pump pulley bolts. 4. Remove the accessory drive belt. 5. Remove the 4 bolts and the coolant pump pulley. 6. Remove the 4 bolts and the coolant pump. Discard the O-ring seal. 7. Inspect the sealing surfaces and clean with metal surface prep. Follow the directions on the packaging. Installation 1. NOTICE: Align the bolt holes with the bosses prior to insertion of the coolant pump and insert the pump straight into the coolant pump cavity. Do not rotate the coolant pump once installed in the coolant pump cavity or damage to the O-ring seal can occur, causing the coolant pump to leak. NOTE: Install a new O-ring seal and lubricate with clean engine coolant. Install the coolant pump and 4 bolts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2411 - Tighten to 25 Nm (18 lb-ft). 2. Install the coolant pump pulley and 4 bolts. 3. Install the accessory drive belt. 4. Tighten the 4 bolts for the coolant pump pulley. - Tighten to 25 Nm (18 lb-ft). 5. Install the cooling fan. For additional information, refer to Cooling Fan See: Radiator Cooling Fan/Fan Blade/Service and Repair. 6. Fill the engine cooling system. For addition information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Cooling System Draining, Filling And Bleeding. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2416 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2417 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2418 Catalytic Converter: Service and Repair Exhaust System - Exploded View Expedition and Navigator NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. Expedition EL and Navigator L NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2419 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Install 16 new exhaust manifold studs. Tighten to................................................................................ ....................................................................................................................12 Nm (106 lb-in). Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown. Tighten to.............................................................................................................................................. .........................................................25 Nm (18 lb-ft). Exhaust Manifold - LH Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown. Tighten to.............................................................................................................................................. .........................................................25 Nm (18 lb-ft). Exhaust Manifold - RH Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2425 Exhaust Manifold: Removal and Replacement Exhaust Manifold - LH Exhaust Manifold - LH Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the Air Cleaner (ACL) outlet pipe. 3. Remove the degas bottle. 4. NOTICE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems. Remove the bolt and disconnect the steering shaft and position aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2426 5. Remove the 4 (2 LH and 2 RH) exhaust manifold-to-catalytic converter nuts. Four-Wheel Drive (4WD) vehicles 6. Remove the front driveshaft. All vehicles 7. Remove the 8 exhaust manifold nuts, the 8 studs and the exhaust manifold. - Discard the exhaust manifold nuts and studs. 8. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Remove and discard the 2 exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep. 9. Inspect the exhaust manifold. Installation All vehicles 1. Using 2 new exhaust manifold gaskets and 8 new studs, position the 2 gaskets and exhaust manifold and install the 8 studs. - Tighten to 12 Nm (106 lb-in). 2. Using new exhaust manifold nuts, install the 8 nuts. - Tighten to 25 Nm (18 lb-ft) in the sequence shown. Exhaust Manifold - LH 4WD vehicles 3. Install the front driveshaft. All vehicles 4. NOTICE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2427 to Air Bag Systems. Connect the steering shaft and install the bolt. To install, tighten to 30 Nm (22 lb-ft). 5. Install the 4 exhaust manifold-to-catalytic converter nuts. 6. Install the degas bottle. 7. Install the ACL outlet tube. Exhaust Manifold - RH Exhaust Manifold - RH Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2428 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH inner fenderwell. 3. Remove the RH engine support insulator. For additional information, refer to Engine Support Insulators See: Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement. 4. Remove the 2 bolts and the exhaust manifold heat shield. 5. Remove the 8 exhaust manifold nuts, the 8 studs and the exhaust manifold. - Discard the exhaust manifold nuts and studs. 6. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Remove and discard the 2 exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep. 7. Inspect the exhaust manifold. Installation 1. Using 2 new exhaust manifold gaskets and 8 new studs, position the 2 gaskets and exhaust manifold and install the 8 studs. - Tighten to 12 Nm (106 lb-in). 2. Using 8 new exhaust manifold nuts, install the 8 nuts. - Tighten to 25 Nm (18 lb-ft) in the sequence shown. Exhaust Manifold - RH 3. Position the exhaust manifold heat shield and install the 2 bolts. - Tighten to 10 Nm (89 lb-in). 4. Install the RH engine support insulator. For additional information, refer to Engine Support Insulators See: Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Removal and Replacement. 5. Install the RH inner fenderwell. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition and Navigator NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. Expedition EL and Navigator L Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2433 NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2434 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 isolators as they deteriorate the rubber. NOTE: The exhaust Y-pipe dual catalytic converter is a 2-piece assembly. The RH and LH converters can be serviced separately as needed. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors. 3. Remove the transmission support crossmember. 4. Loosen the exhaust and transmission mounting bracket cap bolt. Rear Wheel Drive (RWD) vehicles 5. Remove the 3 bolts and then slide off the exhaust and transmission mounting bracket from the exhaust Y-pipe dual catalytic converter. Four-Wheel Drive (4WD) vehicles 6. NOTE: On Four-Wheel Drive (4WD) vehicles, the exhaust and transmission mounting bracket will not slide off the exhaust Y-pipe dual catalytic converter until the exhaust Y-pipe dual catalytic converter is removed from the vehicle. NOTE: RH side shown, LH side similar. Remove the 4 bolts from the exhaust and transmission mounting bracket. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2435 All vehicles 7. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts. 8. NOTE: LH catalytic converter-to-exhaust manifold nuts shown, RH similar. Remove the 4 exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. - Discard the nuts. 9. Remove the exhaust Y-pipe dual catalytic converter from the vehicle. 4WD vehicles 10. If necessary, remove the exhaust and transmission mounting bracket from the exhaust Y-pipe dual catalytic converter. All vehicles 11. If necessary, loosen the RH catalytic converter-to-LH catalytic converter Torca(R) clamp. 12. If necessary, separate the RH catalytic converter from the LH catalytic converter. Installation All vehicles NOTICE: Do not tighten the fasteners until all components are assembled and aligned, making sure to tighten all fasteners beginning at the front of the vehicle. For additional information, refer to Exhaust System Alignment See: Service and Repair. NOTE: Clean the mating surfaces of the exhaust manifold outlet flare and the exhaust Y-pipe dual catalytic converter inlet flares. Also clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly. 1. If separated, install RH catalytic converter to the LH catalytic converter. 4WD vehicles 2. If removed, install the exhaust and transmission mounting bracket to the exhaust Y-pipe dual catalytic converter. All vehicles 3. Position the exhaust Y-pipe dual catalytic converter into the vehicle. 4. Install the 2 new RH catalytic converter-to-exhaust manifold nuts and tighten in the following sequence: 1. Tighten the RH lower catalytic converter-to-exhaust manifold nut. - Tighten to 40 Nm (30 lb-ft). 2. Tighten the RH upper catalytic converter-to-exhaust manifold nut. - Tighten to 40 Nm (30 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2436 5. Install the 2 new LH catalytic converter-to-exhaust manifold nuts and tighten in the following sequence: 1. Snug the LH inner catalytic converter-to-exhaust manifold nut. 2. Tighten the LH outer catalytic converter-to-exhaust manifold nut. - Tighten to 40 Nm (30 lb-ft). 3. Tighten the LH inner catalytic converter-to-exhaust manifold nut. - Tighten to 40 Nm (30 lb-ft). 6. If loosened, tighten the RH catalytic converter-to-LH catalytic converter Torca(R) clamp. - Tighten to 55 Nm (41 lb-ft). 7. Install the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and tighten in the following sequence: 1. Snug the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt. 2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt. - Tighten to 63 Nm (46 lb-ft). 3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt. - Tighten to 63 Nm (46 lb-ft). 4WD vehicles 8. NOTE: RH side shown, LH side similar. Install the 4 exhaust and transmission mounting bracket-to-transmission bolts. - Tighten to 90 Nm (66 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2437 RWD vehicles 9. Slide on the exhaust and transmission mounting bracket to the exhaust Y-pipe dual catalytic converter and install the 3 exhaust and transmission mounting bracket-to-transmission bolts. Tighten to 90 Nm (66 lb-ft). All vehicles 10. Tighten the exhaust and transmission mounting bracket cap bolt. - Tighten to 35 Nm (26 lb-ft). 11. Install the transmission support crossmember. 12. Connect the HO2S and CMS electrical connectors. 13. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition and Navigator NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. Expedition EL and Navigator L Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2442 NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2443 Muffler: Service and Repair Muffler And Tailpipe Muffler and Tailpipe Removal NOTICE: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the isolator. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: LH side shown, RH side similar. If equipped, remove the 6 bolts and transfer case skid plate. 3. Loosen the tail pipe or resonator-to-muffler assembly Torca(R) clamp. 4. Remove the 2 isolator and bracket assembly bolts and remove: - the tail pipe for Expedition models. - the resonator for Navigator models. 5. Using a suitable jackstand, support the muffler. 6. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts. 7. NOTICE: Make sure not to make contact with the axle boots while routing the muffler assembly outlet over the rear axle or damage to the boots may result. Detach the isolators from the muffler assembly and remove from the vehicle. Installation NOTICE: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the isolator. This can lead to separation of the isolators from the exhaust hanger bracket during vehicle operation. 1. NOTE: Clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2444 NOTE: Check the exhaust hanger isolators for wear or damage, install new isolators, if necessary. Install the muffler assembly into the vehicle and attach the isolators. 2. Install the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and tighten in the following sequence: 1. Snug the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt. 2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt. - Tighten to 63 Nm (46 lb-ft). 3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt. - Tighten to 63 Nm (46 lb-ft). 3. Install the tail pipe for Expedition models or the resonator for Navigator models and install the isolator and 2 bracket assembly bolts. - Tighten to 25 Nm (18 lb-ft). 4. Tighten the tail pipe or resonator-to-muffler assembly Torca(R) clamp. - Tighten to 48 Nm (35 lb-ft). 5. 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. 6. NOTE: LH side shown, RH side similar. If equipped, install the transfer case skid plate and 6 bolts. - Tighten to 25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2451 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2452 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2453 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts Engine Control Module: Customer Interest Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 2462 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 2463 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 2468 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 2469 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls Delayed/Harsh Downshifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls Delayed/Harsh Downshifts > Page 2475 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls Delayed/Harsh Downshifts > Page 2476 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 2481 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 2482 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2483 Engine Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2484 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2485 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2486 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2487 Engine Control Module: Diagrams C175B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2488 C175B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2489 C175B Part 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2490 C175E Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2491 C175E Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2492 C175E Part 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2493 C175T Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2494 C175T Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2497 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2498 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) Removal and Installation 1. NOTE: Refer to Computers and Control Systems Information for correct Vehicle Communication Module (VCM) hook-up procedure. If servicing the PCM, connect the scan tool to the vehicle. Allow the scan tool to identify the vehicle and obtain configuration data. - All programmable module information will automatically be retrieved by the VCM. 2. Disconnect the battery ground cable. 3. Disconnect the 3 PCM electrical connectors. 4. Remove the 2 stud bolts and the PCM. - To install, tighten to 9 Nm (80 lb-in). 5. NOTE: If the Instrument Cluster (IC) or the PCM is being replaced (or both), the parameters must be reset in both modules or the vehicle will experience a Passive Anti-Theft System (PATS) no-start. This will occur even if the vehicle is not equipped with PATS. To install, reverse the removal procedure. 6. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2502 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2503 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Service and Repair Fuel Pump Control Unit: Service and Repair Fuel Pump Control Module Removal and Installation 1. Disconnect the fuel pump control module electrical connector. 2. Remove the 2 bolts and the fuel pump control module. - To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2511 Fuel Pump Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2512 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2516 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2517 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Accelerator Pedal Position Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2523 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2524 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2525 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2529 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2530 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls Air Flow Meter/Sensor: Description and Operation Electronic Engine Controls Electronic Engine Controls Mass Air Flow (MAF) Sensor The MAF sensor: - sends the PCM a signal indicating mass airflow rate of air entering the engine. - incorporates the Intake Air Temperature (IAT) sensor. For removal and installation, refer to Mass Air Flow (MAF) Sensor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 2533 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 2534 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Page 2535 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 > Page 2540 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2543 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2544 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2545 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation LH Camshaft Position (CMP) sensor 1. Remove the Air Cleaner (ACL) outlet pipe. All CMP sensors 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2555 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2556 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2557 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt from the A/C compressor pulley. 3. Disconnect the A/C compressor electrical connector. 4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2558 7. To install, reverse the removal procedure. 8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2562 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2563 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2564 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor and discard. - To install, tighten to 10 Nm (89 lb-in). - Coat the new CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2570 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2571 Fuel Level Sensor: Service and Repair Fuel Pump Module Fuel Pump Module 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2572 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. All fuel tanks 1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank. 127L (33.5 gal) fuel tank 2. Remove the 4 nuts and the Fuel Pump (FP) module cover. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the return fuel tube-to-FP module quick connect coupling. All fuel tanks 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. 5. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring. 106L (28 gal) fuel tank 6. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2573 Remove the FP and FP O-ring seal. If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange. - Discard the FP O-ring seal. 127L (33.5 gal) fuel tank 7. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: Note the location of the FP alignment tabs. Remove the FP module assembly. Remove and discard the O-ring seal. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2577 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2578 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2579 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor 106L (28 Gal) Fuel Tank 125L (33 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 2582 Removal and Installation All fuel tanks 1. Remove the fuel tank. 106L (28 gal) fuel tank 2. Disconnect the fuel supply tube-to-heat shield pushpin retainer. 125L (33 gal) fuel tank 3. Remove the fuel tank heat shield retainer(s). All fuel tanks 4. Remove the fuel tank heat shield. 5. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-fuel vapor/grade vent valves quick connect couplings. 6. Disconnect the FTP sensor and vapor tube assembly-to-fuel pump module quick connect coupling. 7. Remove the FTP sensor and vapor tube assembly from the fuel tank. 8. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 2583 Fuel Tank Pressure Sensor: Service and Repair Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 2584 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2588 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2589 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2590 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1 > Page 2595 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2598 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2599 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2600 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2611 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2612 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2613 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2614 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2615 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2618 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2619 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2620 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2623 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2626 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. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. - Apply penetrating lubricant to the HO2S to assist in removal. Installation 1. Install the HO2S. - Apply a light coat of high temperature nickel anti-seize lubricant to the HO2S threads prior to installation. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft). 2. Connect the HO2S electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2627 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 3. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. - Apply penetrating lubricant to the CMS to assist in removal. Installation 1. Install the CMS. - Apply a light coat of high temperature nickel anti-seize lubricant to the CMS threads prior to installation. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft). 2. Connect the CMS electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Power Steering Pressure Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2631 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2632 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2635 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2642 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2645 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2646 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal 1. Remove the Throttle Body (TB). 2. 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 ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 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 1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB. 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). 2. Install the TB. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2651 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Accelerator Pedal Position Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2660 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2661 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2662 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2666 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2667 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls Air Flow Meter/Sensor: Description and Operation Electronic Engine Controls Electronic Engine Controls Mass Air Flow (MAF) Sensor The MAF sensor: - sends the PCM a signal indicating mass airflow rate of air entering the engine. - incorporates the Intake Air Temperature (IAT) sensor. For removal and installation, refer to Mass Air Flow (MAF) Sensor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls > Page 2670 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls > Page 2671 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Page 2672 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Inertia Fuel Shutoff Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2682 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2683 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2684 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2685 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2686 Inertia Fuel Shutoff Switch: Service and Repair Inertia Fuel Shutoff (IFS) Switch Removal and Installation 1. NOTE: The Inertia Fuel Shutoff (IFS) switch is located behind the LH quarter trim panel access cover. Remove the LH quarter trim panel access cover. 2. Remove the power liftgate motor electrical connector pushpins from the power liftgate motor bracket. 3. NOTE: Slide the IFS switch out below the power liftgate motor bracket. Remove the 2 bolts and the IFS switch. To install, tighten to 2 Nm (18 lb-in). 4. Disconnect the IFS switch electrical connector. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2690 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2693 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 Expedition 2wd Workshop Manual (V8-5.4L (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 2694 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal 1. Remove the Throttle Body (TB). 2. 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 ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 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 1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB. 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). 2. Install the TB. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 > Page 2700 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 2703 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2704 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2705 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation LH Camshaft Position (CMP) sensor 1. Remove the Air Cleaner (ACL) outlet pipe. All CMP sensors 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2709 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2710 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2711 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt from the A/C compressor pulley. 3. Disconnect the A/C compressor electrical connector. 4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2712 7. To install, reverse the removal procedure. 8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. If a new lock cylinder with keys is replaced, the new PATS keys must be programmed. 4. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2718 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2723 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2726 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2727 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2728 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Engine running..................................................................................................................................... ..............................................379-414 kPa (55-60 psi) Key ON Engine OFF (KOEO)......................... ..................................................................................................................................379-414 kPa (55-60 psi) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2733 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. Remove the cap from the fuel pressure relief valve located on the fuel rail. 2. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 3. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 4. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place 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. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2734 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 695 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2743 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element Removal and Installation 1. Disconnect the Air Cleaner (ACL) outlet pipe from the ACL cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Release the retaining clips and position the ACL cover aside. 4. Remove the ACL element. 5. NOTE: The ACL element must be fully seated into the ACL housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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: 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. 1. Disconnect the battery ground cable. 2. Remove the cap from the fuel pressure relief valve located on the fuel rail. 3. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 4. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the Fuel Pressure Test Kit and relieve the fuel pressure. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 2748 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order Firing Order: Specifications Firing Order Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Firing Order > Page 2753 Firing Order: Specifications Engine Cylinder Identification Engine Cylinder Identification Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Base ignition timing.............................................................................................................................. ........................10° Before Top Dead Center (BTDC) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... .................................1.05 ± 0.05 mm (0.039-0.043 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2761 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................12 Nm (106 lb-in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2762 Spark Plug: Application and ID Spark plug............................................................................................................................................ ...................................................................HJFS-24FP Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2763 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2764 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Engine Ignition - RH Engine Ignition - LH 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2767 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal NOTICE: The spark plug procedure must be followed exactly or damage to the cylinder head and spark plug will result. 1. Remove the ignition coil-on-plug. For additional information, refer to Ignition Coil-On-Plug See: Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plug. 3. Inspect the spark plug. Installation 1. Adjust the spark plug gap as necessary. For the correct spark plug gap specification, refer to Specifications. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Install the spark plug. - To install, tighten to 12 Nm (106 lb-in). 3. Install the ignition coil. For additional information, refer to Ignition Coil-On-Plug See: Ignition System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2771 Compression Check: Testing and Inspection Engine Component Tests The following component tests are used to diagnose engine concerns. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2772 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2777 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2778 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2779 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2783 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2784 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls Air Flow Meter/Sensor: Description and Operation Electronic Engine Controls Electronic Engine Controls Mass Air Flow (MAF) Sensor The MAF sensor: - sends the PCM a signal indicating mass airflow rate of air entering the engine. - incorporates the Intake Air Temperature (IAT) sensor. For removal and installation, refer to Mass Air Flow (MAF) Sensor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 2787 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 2788 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Page 2789 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2793 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2794 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2795 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Brake Signal: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2799 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2800 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 2803 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 2 > Page 2808 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2811 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2812 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2813 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation LH Camshaft Position (CMP) sensor 1. Remove the Air Cleaner (ACL) outlet pipe. All CMP sensors 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2823 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2824 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2825 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt from the A/C compressor pulley. 3. Disconnect the A/C compressor electrical connector. 4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2826 7. To install, reverse the removal procedure. 8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2830 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2831 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2835 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2836 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2840 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2841 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2842 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts Engine Control Module: Customer Interest Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 2851 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 2852 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 2857 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 2858 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 2864 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 2865 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 2870 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 2871 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2872 Engine Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2873 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2874 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2875 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2876 Engine Control Module: Diagrams C175B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2877 C175B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2878 C175B Part 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2879 C175E Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2880 C175E Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2881 C175E Part 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2882 C175T Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2883 C175T Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2886 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2887 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) Removal and Installation 1. NOTE: Refer to Computers and Control Systems Information for correct Vehicle Communication Module (VCM) hook-up procedure. If servicing the PCM, connect the scan tool to the vehicle. Allow the scan tool to identify the vehicle and obtain configuration data. - All programmable module information will automatically be retrieved by the VCM. 2. Disconnect the battery ground cable. 3. Disconnect the 3 PCM electrical connectors. 4. Remove the 2 stud bolts and the PCM. - To install, tighten to 9 Nm (80 lb-in). 5. NOTE: If the Instrument Cluster (IC) or the PCM is being replaced (or both), the parameters must be reset in both modules or the vehicle will experience a Passive Anti-Theft System (PATS) no-start. This will occur even if the vehicle is not equipped with PATS. To install, reverse the removal procedure. 6. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2891 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2892 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2893 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor and discard. - To install, tighten to 10 Nm (89 lb-in). - Coat the new CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2899 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2900 Fuel Level Sensor: Service and Repair Fuel Pump Module Fuel Pump Module 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2901 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. All fuel tanks 1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank. 127L (33.5 gal) fuel tank 2. Remove the 4 nuts and the Fuel Pump (FP) module cover. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the return fuel tube-to-FP module quick connect coupling. All fuel tanks 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. 5. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring. 106L (28 gal) fuel tank 6. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2902 Remove the FP and FP O-ring seal. If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange. - Discard the FP O-ring seal. 127L (33.5 gal) fuel tank 7. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: Note the location of the FP alignment tabs. Remove the FP module assembly. Remove and discard the O-ring seal. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2906 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2907 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2908 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor 106L (28 Gal) Fuel Tank 125L (33 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 2911 Removal and Installation All fuel tanks 1. Remove the fuel tank. 106L (28 gal) fuel tank 2. Disconnect the fuel supply tube-to-heat shield pushpin retainer. 125L (33 gal) fuel tank 3. Remove the fuel tank heat shield retainer(s). All fuel tanks 4. Remove the fuel tank heat shield. 5. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-fuel vapor/grade vent valves quick connect couplings. 6. Disconnect the FTP sensor and vapor tube assembly-to-fuel pump module quick connect coupling. 7. Remove the FTP sensor and vapor tube assembly from the fuel tank. 8. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 2912 Fuel Tank Pressure Sensor: Service and Repair Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 2913 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2921 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2922 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 14-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 14-3 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 14-4 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 14-5 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2943 Information Bus: Description and Operation Communications Network NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). Multiplexing is a method of sending 2 or more signals simultaneously over a single circuit. Multiplexing is used to allow 2 or more electronic modules (nodes) to communicate simultaneously over a twisted-wire pair [data (+) and data (-)] network. The information or messages that can be communicated on these wires consists of commands, status or data. The advantage of using multiplexing is to reduce the weight of the vehicle by reducing the number of redundant components and electrical wiring. The vehicle has 2 module communication networks which are connected to the Data Link Connector (DLC), located under the instrument panel: - High Speed Controller Area Network (HS-CAN) - Medium Speed Controller Area Network (MS-CAN) The HS-CAN and MS-CAN are defined by various ISO documents: - ISO 11898 specifies the electrical, mechanical, and procedural interface for Controller Area Network (CAN) serial communication technology. - ISO 15765 specifies network-layer protocol and timing parameters for CAN-based systems. - ISO 14229 specifies a common set of unified diagnostics and changes the way PIDs, DTCs and active commands are processed and displayed on the scan tool. Network Topology Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2944 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: - ACM - APIM - Audio DSP module (Navigator only) - Audio RCU (if equipped) - DCSM (if equipped) - DSM (if equipped) - HVAC module - IC - LTM (if equipped) - PAM (if equipped) - PRB (if equipped) - SDARS module (if equipped) - SJB - RETM (if equipped) 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2945 - PCM - RCM - TCM - VDM (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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 the medium and high speed Controller Area Network (CAN) communications. CAN is a method for transferring data among distributed electronic modules via a serial data bus. The vehicle is equipped with 2 module communication networks: - Medium Speed 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 data transfer speed of 125 Kbps for bus messages and is designed for general information transfer. The network will remain operational, but at a degraded level when certain circuit faults are present. The MS-CAN may remain operational with only one termination resistor present. In the event that one 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. The module to which the network circuit is open may repeatedly send network messages indicating there has been partial data received. This type of message is referred to as a Negative-Acknowledge (NACK) message. Repeated NACK messages may "load" the network with too much activity causing intermittent no communication to other network modules and/or the scan tool. The following modules are on the MS-CAN: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2948 - Audio Control Module (ACM) - Accessory Protocol Interface Module (APIM) - Audio Digital Signal Processing (DSP) module (if equipped) - Audio Rear Control Unit (RCU) (if equipped) - Driver Seat Module (DSM) (if equipped) - Dual Climate Controlled Seat Module (DCSM) (if equipped) - HVAC module - Electronic Automatic Temperature Control (EATC) (if equipped) - HVAC module - Electronic Manual Temperature Control (EMTC) (if equipped) - Instrument Cluster (IC) - Liftgate/Trunk Module (LTM) (if equipped) - 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 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 HS-CAN may remain operational with only one termination resistor present. 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. The module to which the network circuit is open may repeatedly send network messages indicating there has been partial data received. This type of message is referred to as a Negative-Acknowledge (NACK) message. Repeated NACK messages may "load" the network with too much activity causing intermittent no communication to other network modules and/or the scan tool. The following modules are on the HS-CAN: - 4X4 control module (if equipped) - ABS module - Accessory Protocol Interface Module (APIM) - IC - PCM - Restraints Control Module (RCM) - Transmission Control Module (TCM) - Vehicle Dynamics Module (VDM) (if equipped) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2949 The following fault chart describes the specific HS-CAN failures and their resulting symptom: 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2950 Controller Area Network (CAN) Module Communication Message Chart (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2951 Controller Area Network (CAN) Module Communication Message Chart (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2952 Controller Area Network (CAN) Module Communication Message Chart (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2953 Controller Area Network (CAN) Module Communication Message Chart (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2954 Controller Area Network (CAN) Module Communication Message Chart (Part 5) 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2955 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 Y, to diagnose No Power To The Scan Tool. See: Pinpoint Tests/Pinpoint Test Y: 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2956 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 Configurable modules accommodate a variety of vehicle options, eliminating the need for many unique modules for one vehicle line. These modules must be configured when replaced as part of a repair procedure. Configurable modules should not be exchanged between vehicles since the settings are unique to each vehicle. Failure to configure a new module may result in improper operation and/or 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: Service and Repair. 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2957 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 On-Line Automotive Service Information System (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 The PCM contains 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 will not reflect customer preference items that have been changed from the default state. These items will need to be changed using programmable parameters after the module is configured. NOTE: It is not necessary to obtain As-Built data unless directed to do so by the scan tool. This data may be accessed from the technician service publication website. The following chart lists As-Built data addresses and describes specific module configuration information: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2958 Module Configuration And Parameter Chart (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2959 Module Configuration And Parameter Chart (Part 2) Inspection And Verification 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2960 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 faulty 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2961 U0001-U0121 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2962 U0121-U0155 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2963 U0155-U0184 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2964 U0184:00-U0238 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2965 U0238:00-U2011 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2966 U2013-U3000:88 Module Configuration Module Configuration Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2967 B2477-B2900 / P0602-P1639 / U201A:51-U0300 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2968 U2050-U2101:00 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2969 Information Bus: Symptom Related Diagnostic Procedures Communications Network Symptom Chart Symptom Chart (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2970 Symptom Chart (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2971 Symptom Chart (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2972 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 25, Electronic Engine Controls - 5.4L 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 IF 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 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): ABS module, Accessory Protocol Interface Module (APIM), Instrument Cluster (IC), 4x4 control module, Restraints Control Module (RCM), PCM, Transmission Control Module (TCM) or Vehicle Dynamics Module (VDM)? Yes If "pass" or a DTC was listed next to the PCM, a network fault is not currently present. Go To Pinpoint Test U to diagnose an intermittent HS-CAN fault condition. See: Pinpoint Test U: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Respo 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 T to diagnose no HS-CAN communication. See: Pinpoint Test T: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool ------------------------------------------------- A2 VERIFY COMPUTERS AND CONTROL SYSTEMS INFORMATION PINPOINT TEST QA HAS BEEN CARRIED OUT - Verify that pinpoint test QA has been carried out. - Has pinpoint test QA been carried out? Yes GO to A3. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2973 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 GO to A5. No GO to A4. ------------------------------------------------- A4 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM AND THE DLC FOR AN OPEN - Disconnect: PCM C175b. - Measure the resistance between the PCM C175b-59, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the PCM C175b-43, 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 A5. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2974 ------------------------------------------------- A5 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 A6. No CONNECT the negative battery cable. Go To Pinpoint Test W. See: Pinpoint Test W: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Respond ------------------------------------------------- A6 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. - Is the voltage greater than 6 volts? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No GO to A7. ------------------------------------------------- A7 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2975 network test with the scan tool. ------------------------------------------------Pinpoint Test B: The ABS Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test B: 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 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 circuit CBB52 (GN/WH) and 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 B: 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. ------------------------------------------------- B1 CHECK THE ABS MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: ABS Module C135. - Ignition ON. - Measure the voltage between the ABS module C135-1, circuit SBB69 (GY/RD), C135-8, circuit CBB52 (GN/WH), and C135-32, circuit SBB68 (GN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to B2. No VERIFY the Battery Junction Box (BJB) fuses 52 (10A), 68 (60A) and 69 (60A) are 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. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2976 B2 CHECK THE ABS MODULE GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the ABS module C135-16, circuit GD120 (BK/GN), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to B3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- B3 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 Data Link Connector (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 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 ABS MODULE OPERATION - Disconnect the ABS module connector. - Check for: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2977 - 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 C: The Instrument Cluster (IC) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test C: 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 Medium Speed Controller Area Network (MS-CAN) connection to the IC. Voltage for the IC is provided by circuits CBP29 (WH/VT) and SBP26 (YE/RD). Circuit GD133 (BK) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - IC PINPOINT TEST C: 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. ------------------------------------------------- C1 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2978 - Is the resistance between 54 and 66 ohms? Yes GO to C2. No GO to C4. ------------------------------------------------- C2 CHECK THE IC GROUND CIRCUIT FOR AN OPEN - Measure the resistance between the IC C220-6, circuit GD133 (BK), harness side and ground. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. 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 IC VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Disconnect: IC C220. - Ignition ON. - Measure the voltage between the IC C220-1, circuit SBP26 (YE/RD) harness side and ground; and between the IC C220-14, circuit CBP29 (WH/VT) harness side and ground. - Are the voltages greater than 10 volts? Yes GO to C5. No VERIFY the SJB fuse 26 (10A) or fuse 29 (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. ------------------------------------------------- C4 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 Data Link Connector (DLC) C251-6, circuit VDB04 (WH/BU), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2979 - 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 C5. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- C5 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 GO to C6. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2980 ------------------------------------------------- C6 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 D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool 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 CBP32 (GN/VT), 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 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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2981 ------------------------------------------------- D1 CHECK THE RCM CONNECTION - Ignition OFF. - Depower the SRS. Refer to Air Bag Systems. - Disconnect: RCM C310a. - Disconnect: RCM C310b. - Are RCM C310a-24, RCM C310b-17 and C310b-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 - Repower the SRS. Refer to Air Bag Systems. - Ignition ON. - Measure the voltage between the RCM C310a-24, circuit CBP32 (GN/VT), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to D3. No VERIFY the Smart Junction Box (SJB) fuse 32 (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2982 - Measure the resistance between the RCM C310b-18, circuit VDB04 (WH/BU), harness side and the Data Link Connector (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. - 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2983 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 CBP35 (YE/GY), SBB20 (GN/RD) and SBB27 (BU/RD). Ground is supplied by circuits GD123 (BK/GY) and GD133 (BK). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - 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 27 (20A) or fuse 20 (20A) is OK and the SJB fuse 35 (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: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2984 - 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 Data Link Connector (DLC) C251-6, circuit VDB04 (WH/BU), harness side. - 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2985 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 Vehicle Dynamics Module (VDM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test F: The Vehicle Dynamics Module (VDM) 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 41, Vehicle Dynamic Suspension for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Vehicle Dynamics Module (VDM) 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 VDM. The VDM shares the HS-CAN with the PCM, the Transmission Control Module (TCM), the ABS module, the Restraints Control Module (RCM), the 4X4 control module (if equipped) and the Instrument Cluster (IC). Voltage for the VDM is provided by circuits CBB53 (GN/BN) and SBB48 (VT/RD). Circuit GD120 (BK/GN) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - VDM PINPOINT TEST F: THE VDM 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. ------------------------------------------------- F1 CHECK THE VDM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: VDM C2131a. - Ignition ON. - Measure the voltage between the VDM, harness side and ground as follows: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2986 - Are the voltages greater than 10 volts? Yes GO to F2. No VERIFY the Battery Junction Box (BJB) fuse 48 (30A) or fuse 53 (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. ------------------------------------------------- F2 CHECK THE VDM GROUND CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the VDM, harness side and ground as follows: Are the resistances less than 5 ohms? Yes GO to F3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- F3 CHECK THE CAN CIRCUITS BETWEEN THE DLC AND THE VDM FOR AN OPEN - Measure the resistance between the Data Link Connector (DLC) C251-6, circuit VDB04 (WH/BU), harness side and the VDM C2131a-10, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the DLC C251-14, circuit VDB05 (WH) harness side and the VDM C2131a-9, circuit VDB05 (WH), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2987 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to F4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- F4 CHECK FOR CORRECT VDM OPERATION - Disconnect all the VDM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the VDM 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 VDM. 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 G: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test G: 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 29, Transmission Controls for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Transmission Control Module (TCM) communicates with the scan tool through the High Speed Controller Area Network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the TCM. The TCM shares the HS-CAN with the PCM, the ABS module, the Restraints Control Module (RCM), the 4X4 control module (if equipped), the Vehicle Dynamics Module (VDM) (if equipped) and the Instrument Cluster (IC). Voltage for the TCM is provided by circuits CBB54 (VT/OG) and SBB31 (WH/RD). Circuit GD113 (BK/YE) provides ground. This pinpoint test is intended to diagnose the following: - Fuse Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2988 - Wiring, terminals or connectors - TCM PINPOINT TEST G: 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. ------------------------------------------------- G1 CHECK THE TCM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: TCM C1548. - Ignition ON. - Measure the voltage between the TCM, harness side and ground as follows: - Are the voltages greater than 10 volts? Yes GO to G2. No VERIFY the Battery Junction Box (BJB) fuse 26 (15A) or fuse 54 (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. ------------------------------------------------- G2 CHECK THE TCM GROUND CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the TCM, harness side and ground as follows: - Are the resistances less than 5 ohms? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2989 Yes GO to G3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- G3 CHECK THE HS-CAN CIRCUITS BETWEEN THE TCM AND THE DLC FOR AN OPEN - Measure the resistance between the TCM C1548-6, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the TCM C1548-2, 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 G4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- G4 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. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2990 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 SJB fuse 5 (10A). Circuit GD138 (BK/WH) 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. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- H1 CHECK THE SJB FUSE FOR VOLTAGE - Ignition OFF. - NOTE: Measurements are taken with the fuses installed. - Measure the voltage between the SJB fuse 5 (10A) and ground. - Is the voltage greater than 10 volts? Yes GO to H2. No VERIFY the SJB fuse 5 (10A) is OK. If OK, GO to H4. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2991 H2 CHECK THE SJB GROUND CIRCUITS FOR AN OPEN - Disconnect: Negative Battery Cable. - Disconnect: SJB C2280d. - Measure the resistance between the SJB, harness side and ground as follows: - Are the resistances less than 5 ohms? Yes GO to H3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H3 CHECK THE MS-CAN CIRCUITS BETWEEN THE SJB AND THE DLC FOR AN OPEN - Disconnect: SJB C2280b. - Measure the resistance between the SJB C2280b-37, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the SJB C2280b-38, 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 H4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H4 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2992 - 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 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 54, Manual 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 CBP37 (WH) and SBP15 (WH/RD). Circuit GD133 (BK) 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 C2357a (EMTC) or C228a (EATC). - Ignition ON. - Measure the voltage between the HVAC module C228a-12 or C2357a-12, circuit CBP37 (WH), and the HVAC moduleC228a-13 or C2357a-13, circuit SBP15 (WH/RD) and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2993 - Is the voltage greater than 10 volts? Yes GO to I2. No VERIFY the SJB fuse 15 (10A) or 37 (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. ------------------------------------------------- I2 CHECK THE HVAC MODULE GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the HVAC module C228a-23 or C2357a-23, circuit GD133 (BK) 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-25 or C2357a-25, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the HVAC module C228a-26 or C2357a-26, 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2994 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. - 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 Liftgate/Trunk Module (LTM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test J: The Liftgate/Trunk Module (LTM) 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 109, Power Liftgate/Retractable Running Boards for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Liftgate/Trunk Module (LTM) 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 LTM. Voltage for the LTM is provided by circuits SBP14 (BN/RD) and SBB36 (GN/RD). Circuit GD149 (BK/GY) provides ground. This pinpoint test is intended to diagnose the following: - Fuses - Wiring, terminals or connectors - LTM PINPOINT TEST J: THE LTM 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 LTM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2995 - Ignition OFF. - Disconnect: LTM C4174a. - Ignition ON. - Measure the voltage between the LTM C4174a-4, circuit SBB36 (GN/RD), harness side and ground and between the LTM C4174a-9, circuit SBP14 (BN/RD), harness side and ground. - Are the voltages greater than 10 volts? Yes GO to J2. No VERIFY the SJB fuse 14 (10A) and Battery Junction Box (BJB) fuse 36 (30A) are 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 LTM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the LTM C4174a-1, circuit GD149 (BK/GY), 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 LTM AND THE DLC FOR AN OPEN - Disconnect: LTM C4174b. - Measure the resistance between the LTM C4174b-11, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2996 - Measure the resistance between the LTM C4174b-10, 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 LTM OPERATION - Disconnect all the LTM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the LTM 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 LTM. 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 Audio Control Module (ACM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test K: 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2997 Normal Operation The Audio Control Module (ACM) 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 ACM. Voltage for the ACM is provided by circuit SBP39 (WH/RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - ACM PINPOINT TEST K: 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. ------------------------------------------------- K1 CHECK THE ACM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: ACM C240a. - Ignition ON. - Measure the voltage between the ACM C240a-1, circuit SBP39 (WH/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to K2. No VERIFY the SJB fuse 39 (20A) 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 ACM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the ACM C240a-13, circuit GD114 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to K3. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2998 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 ACM AND THE DLC FOR AN OPEN - Disconnect: ACM C240c. - Measure the resistance between the ACM C240c-15, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the base ACM C240c-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 K4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- K4 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. 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 network test with the scan tool. ------------------------------------------------Pinpoint Test L: The Audio Digital Signal Processing (DSP) Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2999 Pinpoint Test L: The Audio Digital Signal Processing (DSP) 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 audio Digital Signal Processing (DSP) 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 audio DSP module. Voltage for the audio DSP module is provided by circuits SBP38 (BN/RD) and SBP40 (VT/RD). Three circuits GD114 (BK/BU) provide ground. This pinpoint test is intended to diagnose the following: - Fuses - Wiring, terminals or connectors - Audio DSP module PINPOINT TEST L: THE AUDIO DSP 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. ------------------------------------------------- L1 CHECK THE AUDIO DSP MODULE VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Audio DSP Module C2364a. - Ignition ON. - Measure the voltage between the audio DSP module, harness side and ground as follows: - Are the voltages greater than 10 volts? Yes GO to L2. No VERIFY the SJB fuse 38 (20A) or fuse 40 (20A) 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. ------------------------------------------------- L2 CHECK THE AUDIO DSP MODULE GROUND CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the audio DSP module, harness side and ground as follows: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3000 - Are the resistances 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 DLC AND THE AUDIO DSP MODULE FOR AN OPEN - Disconnect: Audio DSP Module C2364c. - Measure the resistance between the audio DSP module C2364c-11, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the audio DSP module C2364c-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 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 AUDIO DSP MODULE OPERATION - Disconnect all the audio DSP module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the audio DSP module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3001 - Is the concern still present? Yes INSTALL a new audio DSP 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 M: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test M: 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 SBP03 (BU/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 M: 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. ------------------------------------------------- M1 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 SBP03 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3002 Yes GO to M2. No VERIFY the SJB fuse 3 (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. ------------------------------------------------- M2 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 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 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 Data Link Connector (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. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to M4. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3003 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 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 N: The Audio Rear Control Unit (RCU) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test N: The Audio Rear Control Unit (RCU) 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 audio Rear Control Unit (RCU) 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 audio RCU. Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the audio RCU. Voltage for the audio RCU is provided by circuit SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Audio RCU PINPOINT TEST N: THE AUDIO RCU 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 AUDIO RCU VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3004 - Disconnect: Audio RCU C3077. - Ignition ON. - Measure the voltage between the audio RCU C3077-16, circuit SBP03 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to N2. No VERIFY the Smart Junction Box (SJB) fuse 3 (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. ------------------------------------------------- N2 CHECK THE AUDIO RCU GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the audio RCU C3077-1, circuit GD114 (BK/BU), harness side and ground. - 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 AUDIO RCU AND THE DLC FOR AN OPEN - Measure the resistance between the audio RCU C3077-8, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the audio RCU C3077-7, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3005 - 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 AUDIO RCU OPERATION - Disconnect the audio RCU connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the audio RCU 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 audio RCU. 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 network test with the scan tool. ------------------------------------------------Pinpoint Test O: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test O: 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 132, Video System 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. Voltage for the RETM is provided by circuit SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - RETM Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3006 PINPOINT TEST O: 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. ------------------------------------------------- O1 CHECK THE RETM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: RETM C949. - Ignition ON. - Measure the voltage between the RETM C949-16, circuit SBP03 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to O2. No VERIFY the SJB fuse 3 (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. ------------------------------------------------- O2 CHECK THE RETM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the RETM C949-1, circuit GD114 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to O3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O3 CHECK THE MS-CAN CIRCUITS BETWEEN THE RETM AND THE DLC FOR AN OPEN - Measure the resistance between the RETM C949-8, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3007 - Measure the resistance between the RETM C949-7, 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 O4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O4 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. 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 network test with the scan tool. ------------------------------------------------Pinpoint Test P: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test P: 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3008 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 SBB45 (GY/RD). Circuit GD133 (BK) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - DSM PINPOINT TEST P: 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. ------------------------------------------------- P1 CHECK THE DSM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: DSM C341b. - Ignition ON. - Measure the voltage between the DSM C341b-1, circuit SBP02 (YE/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to P2. No VERIFY the SJB fuse 2 (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. ------------------------------------------------- P2 CHECK THE DSM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the DSM C341b-24, circuit GD133 (BK), harness side and ground. - Is the resistance less than 5 ohms? Yes Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3009 GO to P3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P3 CHECK THE MS-CAN CIRCUITS BETWEEN THE DSM AND THE DLC FOR AN OPEN - Disconnect: DSM C341d. - Measure the resistance between the DSM C341d-10, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the DSM C341d-9, 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 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 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. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3010 Pinpoint Test Q: The Dual Climate Controlled Seat Module (DCSM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test Q: The Dual Climate Controlled Seat Module (DCSM) 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 119, Climate Controlled Seats for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Dual Climate Controlled Seat Module (DCSM) 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 DCSM. Voltage for the DCSM is provided by circuit SBB08 (VT/RD). Circuit GD138 (BK/WH) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - DCSM PINPOINT TEST Q: THE DCSM 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. ------------------------------------------------- Q1 VERIFY VEHICLE EQUIPMENT - Inspect the vehicle for seat side air bags. - Is the vehicle equipped with seat side air bags? Yes GO to Q2. No GO to Q3. ------------------------------------------------- Q2 CHECK THE DCSM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - WITH SIDE AIR BAGS NOTE: If a seat equipped with a Supplemental Restraint System (SRS) component is being serviced, the SRS must be depowered. Refer to Air Bag Systems. NOTE: The air bag warning lamp illuminates when the Restraints Control Module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate an SRS fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Ignition OFF. - For vehicles with seat side air bags, carry out the following: Depower the SRS. Refer to Air Bag Systems. - Disconnect the driver seat side air bag module C3226. - Disconnect the passenger seat side air bag module C3227. - Connect the negative battery cable. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3011 - Disconnect: DCSM C3265a. - Ignition ON. - Measure the voltage between the DCSM, harness side and ground as follows: - Are the voltages greater than 10 volts? Yes GO to Q4. No VERIFY the Battery Junction Box (BJB) fuse 67 (40A) 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. ------------------------------------------------- Q3 CHECK THE DCSM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: DCSM C3265a. - Ignition ON. - Measure the voltage between the DCSM, harness side and ground as follows: - Are the voltages greater than 10 volts? Yes GO to Q4. No VERIFY the Battery Junction Box (BJB) fuse 67 (40A) 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. ------------------------------------------------- Q4 CHECK THE DCSM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3012 - Disconnect: Negative Battery Cable. - Measure the resistance between the DCSM C3265a-M, circuit GD138 (BK/WH), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to Q5. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q5 CHECK THE MS-CAN CIRCUITS BETWEEN THE DCSM AND THE DLC FOR AN OPEN - Disconnect: DCSM C3265c. - Measure the resistance between the DCSM C3265c-1, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the DCSM C3265c-2, 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 Q6. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q6 CHECK FOR CORRECT DCSM OPERATION - Disconnect all the DCSM connectors. - Check for: corrosion - damaged pins Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3013 - pushed-out pins - Connect all the DCSM 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 DCSM. REPOWER 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. REPOWER the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test R: The Power Running Board (PRB) Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test R: The Power Running Board (PRB) 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 109, Power Liftgate/Retractable Running Boards 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 SBB11 (BU/RD). Circuit GD143 (BK/VT) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PRB module PINPOINT TEST R: 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. ------------------------------------------------- R1 CHECK THE PRB MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: PRB Module C3313b. - Ignition ON. - Measure the voltage between the PRB module C3313b-1, circuit SBB11 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3014 Yes GO to R2. No VERIFY the Battery Junction Box (BJB) fuse 11 (40A) 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. ------------------------------------------------- R2 CHECK THE PRB MODULE GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the PRB module C3313b-4, circuit GD143 (BK/VT), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to R3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- R3 CHECK THE MS-CAN CIRCUITS BETWEEN THE PRB MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the PRB module C3313b-8, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the PRB module C3313b-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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3015 CONNECT the negative battery cable. GO to R4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- R4 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. 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 S: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test S: 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 CBP35 (YE/GY). Circuit GD133 (BK) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PAM PINPOINT TEST S: 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. ------------------------------------------------- S1 CHECK THE PAM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: PAM C4226 (Expedition) or PAM C4014a (Navigator). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3016 - Ignition ON. - For Expedition , measure the voltage between the PAM C4226-18, circuit CBP35 (YE/GY), harness side and ground. - For Navigator, measure the voltage between the PAM C4014a-1, circuit CBP35 (YE/GY), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to S2. No VERIFY the SJB fuse 35 (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. ------------------------------------------------- S2 CHECK THE PAM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - For Expedition, measure the resistance between the PAM C4226-6, circuit GD133 (BK), harness side and ground. - For Navigator, measure the resistance between the PAM C4014a-4, circuit GD133 (BK), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to S3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S3 CHECK THE MS-CAN CIRCUITS BETWEEN THE PAM AND THE DLC FOR AN OPEN Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3017 - For Expedition, measure the resistance between the PAM C4226-4, circuit VDB06 (GY/OG), harness side and the Data Link Connector (DLC) C251-3, circuit VDB06 (GY/OG), harness side. - For Expedition, 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. - For Navigator, measure the resistance between the PAM C4014a-3, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - For Navigator, measure the resistance between the PAM C4014a-11, 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 S4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S4 CHECK FOR CORRECT PAM OPERATION - Disconnect the PAM connector(s). - Check for: corrosion - damaged pins - pushed-out pins - Connect the PAM connector(s) and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3018 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 T: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test T: 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 Medium Speed Controller Area Network (MS-CAN) connection to the APIM. Voltage for the APIM is provided by circuit SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - APIM PINPOINT TEST T: 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. ------------------------------------------------- T1 CHECK THE APIM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Disconnect: APIM C3342. - Ignition ON. - Measure the voltage between the APIM C3342-1, circuit SBP03 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to T2. No VERIFY the Smart Junction Box (SJB) fuse 3 (15A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3019 identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- T2 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. - Are the resistances less than 5 ohms? Yes GO to T3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- T3 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 T4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3020 T4 CHECK THE MS-CAN CIRCUITS BETWEEN THE APIM AND THE DLC 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. - 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 T5. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- T5 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. 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 U: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Respo Communications Network Pinpoint Tests Pinpoint Test U: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3021 Responding During Network Test 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. In the event that one 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 U: 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. ------------------------------------------------- U1 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 U2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U2 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 U3. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3022 No CONNECT the negative battery cable. Go To Pinpoint Test V. See: Pinpoint Test V: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- U3 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 U4. No CONNECT the negative battery cable. Go To Pinpoint Test V. See: Pinpoint Test V: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- U4 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. Is the voltage greater than 6 volts? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No GO to U5. ------------------------------------------------- U5 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE HVAC MODULE DISABLED - Disconnect: SJB Fuses 15 (10A) and 37 (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3023 INSTALL the removed fuses. GO to U6. ------------------------------------------------- U6 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE ACM DISABLED - Disconnect: SJB Fuse 39 (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 K. See: Pinpoint Test K: The Audio Control Module (ACM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to U7. ------------------------------------------------- U7 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE SJB DISABLED - Disconnect: SJB Fuse 5 (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 H. See: Pinpoint Test H: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to U8. ------------------------------------------------- U8 VERIFY VEHICLE EQUIPMENT - DSM - Inspect the vehicle for a DSM. - Is the vehicle equipped with a DSM? Yes GO to U9. No GO to U10. ------------------------------------------------- U9 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE DSM DISABLED - Disconnect: SJB Fuse 2 (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 P. See: Pinpoint Test P: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to U10. ------------------------------------------------- U10 VERIFY VEHICLE EQUIPMENT - LTM Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3024 - Inspect the vehicle for a Liftgate/Trunk Module (LTM). - Is the vehicle equipped with a LTM? Yes GO to U11. No GO to U12. ------------------------------------------------- U11 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE LTM DISABLED - Disconnect: BJB Fuse 36 (30A) and SJB Fuse 14 (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 J. See: Pinpoint Test J: The Liftgate/Trunk Module (LTM) Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to U12. ------------------------------------------------- U12 VERIFY VEHICLE EQUIPMENT - AUDIO RCU, RETM AND SDARS MODULE - Inspect the vehicle for an audio Rear Control Unit (RCU) , a Rear Entertainment Module (RETM) and/or Satellite Digital Audio Receiver System (SDARS) module. - Is the vehicle equipped with any of the following: an audio RCU, an RETM, and/or a SDARS module? Yes GO to U13. No GO to U16. ------------------------------------------------- U13 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE AUDIO RCU, RETM AND SDARS MODULE DISABLED - Disconnect: SJB Fuse 3 (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 U14. No INSTALL the removed fuse. GO to U16. ------------------------------------------------- U14 VERIFY VEHICLE EQUIPMENT - SDARS MODULE - Inspect the vehicle for a SDARS module. - Is the vehicle equipped with a SDARS module? Yes Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3025 GO to U15. No For RETM equipped vehicles, Go To Pinpoint Test O. See: Pinpoint Test O: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool For audio RCU equipped vehicles, Go To Pinpoint Test N. See: Pinpoint Test N: The Audio Rear Control Unit (RCU) Does Not Respond To The Scan Tool ------------------------------------------------- U15 CHECK FOR RESTORED NETWORK COMMUNICATION - Disconnect: SDARS Module C3290. - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes Go To Pinpoint Test M. See: Pinpoint Test M: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool No For RETM equipped vehicles, Go To Pinpoint Test O. See: Pinpoint Test O: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool For audio RCU equipped vehicles, Go To Pinpoint Test N. See: Pinpoint Test N: The Audio Rear Control Unit (RCU) Does Not Respond To The Scan Tool ------------------------------------------------- U16 VERIFY VEHICLE EQUIPMENT - AUDIO DSP MODULE - Inspect the vehicle for an audio Digital Signal Processing (DSP) module. - Is the vehicle equipped with an audio DSP module? Yes GO to U17. No GO to U18. ------------------------------------------------- U17 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE AUDIO DSP MODULE DISABLED - Disconnect: SJB Fuse 38 (20A) and 40 (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 fuses. Go To Pinpoint Test L. See: Pinpoint Test L: The Audio Digital Signal Processing (DSP) Module Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to U18. ------------------------------------------------- U18 VERIFY VEHICLE EQUIPMENT - DCSM - Inspect the vehicle for a Dual Climate Controlled Seat Module (DCSM). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3026 - Is the vehicle equipped with a DCSM? Yes GO to U19. No GO to U20. ------------------------------------------------- U19 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE DCSM DISABLED - Disconnect: BJB Fuse 67 (40A). - 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 Q. See: Pinpoint Test Q: The Dual Climate Controlled Seat Module (DCSM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to U20. ------------------------------------------------- U20 VERIFY VEHICLE EQUIPMENT - PRB MODULE - Inspect the vehicle for a Power Running Board (PRB) module. - Is the vehicle equipped with a PRB module? Yes GO to U21. No GO to U22. ------------------------------------------------- U21 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE PRB MODULE DISABLED - Disconnect: BJB Fuse 11 (40A). - 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 R. See: Pinpoint Test R: The Power Running Board (PRB) Module Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to U22. ------------------------------------------------- U22 VERIFY VEHICLE EQUIPMENT - PAM - Inspect the vehicle for a Parking Aid Module (PAM). - Is the vehicle equipped with a PAM? Yes Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3027 GO to U23. No GO to U24. ------------------------------------------------- U23 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE PAM DISABLED - Disconnect: SJB Fuse 35 (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 S. See: Pinpoint Test S: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to U24. ------------------------------------------------- U24 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE APIM DISABLED - 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 T. See: Pinpoint Test T: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool No CONNECT the APIM. GO to U25. ------------------------------------------------- U25 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE IC DISABLED - Disconnect: SJB Fuse 26 (10A) and 29 (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 C. See: Pinpoint Test C: 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 V. See: Pinpoint Test V: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------V1-V24 Communications Network Pinpoint Tests Pinpoint Test V: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3028 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 - Audio Control Module (ACM) - Accessory Protocol Interface Module (APIM) - Audio Digital Signal Processing (DSP) module (if equipped) - Audio Rear Control Unit (RCU) (if equipped) - Dual Climate Controlled Seat Module (DCSM) (if equipped) - Driver Seat Module (DSM) (if equipped) - HVAC module (if equipped) - Instrument Cluster (IC) - Liftgate/Trunk Module (LTM) (if equipped) - 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) - Data Link Connector (DLC) PINPOINT TEST V: 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: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- V1 CHECK THE DLC PINS FOR DAMAGE 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 - 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 V2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- V2 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3029 side. - Is the resistance between 54 and 66 ohms? Yes GO to V5. No GO to V3. ------------------------------------------------- V3 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. - Is the resistance between 108 and 132 ohms? Yes GO to V7. No GO to V4. ------------------------------------------------- V4 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 V8. No GO to V7. ------------------------------------------------- V5 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3030 VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes GO to V6. No GO to V33. ------------------------------------------------- V6 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE - Connect the 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 VERIFY all module fuses are OK. If OK, REPEAT the network test with the scan tool. ------------------------------------------------- V7 CHECK THE MS-CAN CIRCUITS BETWEEN THE SJB AND THE DLC FOR AN OPEN - Disconnect: SJB C2280b. - Measure the resistance between the SJB C2280b-37, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the SJB C2280b-38, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3031 - Are the resistances less than 5 ohms? Yes VERIFY all module fuses are OK. If OK, CONNECT the SJB. CONNECT the negative battery cable. REPEAT the network test with the scan tool. No REPAIR the circuit in question. CONNECT the SJB. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- V8 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER 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 less than 5 ohms? Yes GO to V9. No CONNECT the negative battery cable. GO to V58. ------------------------------------------------- V9 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE IC DISCONNECTED - Disconnect: IC C220. - 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 V10. No CONNECT all modules. CONNECT the negative battery cable. GO to V59. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3032 V10 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE ACM DISCONNECTED - Disconnect: ACM C240a. - 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 V11. No CONNECT all modules. CONNECT the negative battery cable. GO to V60. ------------------------------------------------- V11 VERIFY VEHICLE EQUIPMENT - AUDIO DSP MODULE - Inspect the vehicle for an audio Digital Signal Processing (DSP) module. Is the vehicle equipped with an audio DSP module? Yes GO to V12. No GO to V13. ------------------------------------------------- V12 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE AUDIO DSP MODULE DISCONNECTED - Disconnect: Audio DSP Module C2364c. - 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 V13. No CONNECT all modules. CONNECT the negative battery cable. GO to V61. ------------------------------------------------- V13 VERIFY VEHICLE EQUIPMENT - HVAC MODULE - Inspect the vehicle for an HVAC module. - Is the vehicle equipped with an HVAC module? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3033 Yes GO to V14. No GO to V15. ------------------------------------------------- V14 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE HVAC MODULE DISCONNECTED - Disconnect: HVAC Module C228a (EATC) or C2357a (EMTC). - 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 V17. No CONNECT all modules. CONNECT the negative battery cable. GO to V62. ------------------------------------------------- V15 VERIFY VEHICLE EQUIPMENT - APIM - Inspect the vehicle for an APIM. - Is the vehicle equipped with an APIM? Yes GO to V16. No GO to V17. ------------------------------------------------- V16 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 V17. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3034 No CONNECT all modules. CONNECT the negative battery cable. GO to V63. ------------------------------------------------- V17 VERIFY VEHICLE EQUIPMENT - AUDIO RCU - Inspect the vehicle for an audio Rear Control Unit (RCU). - Is the vehicle equipped with an audio RCU? Yes GO to V18. No GO to V19. ------------------------------------------------- V18 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE AUDIO RCU DISCONNECTED - Disconnect: Audio RCU C3077. - 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 V19. No CONNECT all modules. CONNECT the negative battery cable. GO to V64. ------------------------------------------------- V19 VERIFY VEHICLE EQUIPMENT - RETM - Inspect the vehicle for a Rear Entertainment Module (RETM). - Is the vehicle equipped with an RETM? Yes GO to V20. No GO to V21. ------------------------------------------------- V20 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE RETM DISCONNECTED - Disconnect: RETM C949. - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3035 - Is the resistance less than 5 ohms? Yes GO to V21. No CONNECT all modules. CONNECT the negative battery cable. GO to V65. ------------------------------------------------- V21 VERIFY VEHICLE EQUIPMENT - DSM - Inspect the vehicle for a Driver Seat Module (DSM). - Is the vehicle equipped with a DSM? Yes GO to V22. No GO to V23. ------------------------------------------------- V22 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE DSM DISCONNECTED - Disconnect: Driver Seat Module C341d. - 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 V23. No CONNECT all modules. CONNECT the negative battery cable. GO to V66. ------------------------------------------------- V23 VERIFY VEHICLE EQUIPMENT - DCSM - Inspect the vehicle for a Dual Climate Controlled Seat Module (DCSM). - Is the vehicle equipped with a DCSM? Yes GO to V24. No GO to V25. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3036 ------------------------------------------------- V24 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE DCSM DISCONNECTED - Disconnect: DCSM C3265c. - 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 V25. No CONNECT all modules. CONNECT the negative battery cable. GO to V67. ------------------------------------------------V25-V48 Communications Network Pinpoint Tests Pinpoint Test V: 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 - Audio Control Module (ACM) - Accessory Protocol Interface Module (APIM) - Audio Digital Signal Processing (DSP) module (if equipped) - Audio Rear Control Unit (RCU) (if equipped) - Dual Climate Controlled Seat Module (DCSM) (if equipped) - Driver Seat Module (DSM) (if equipped) - HVAC module (if equipped) - Instrument Cluster (IC) - Liftgate/Trunk Module (LTM) (if equipped) - 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) - Data Link Connector (DLC) PINPOINT TEST V: 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3037 NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- V25 VERIFY VEHICLE EQUIPMENT - SDARS MODULE - Inspect the vehicle for a Satellite Digital Audio Receiver System (SDARS) module. - Is the vehicle equipped with a SDARS module? Yes GO to V26. No GO to V27. ------------------------------------------------- V26 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE SDARS MODULE DISCONNECTED - Disconnect: SDARS Module 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 V27. No CONNECT all modules. CONNECT the negative battery cable. GO to V68. ------------------------------------------------- V27 VERIFY VEHICLE EQUIPMENT - PRB MODULE - Inspect the vehicle for a Power Running Board (PRB) module. - Is the vehicle equipped with a PRB module? Yes GO to V28. No GO to V29. ------------------------------------------------- V28 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE PRB MODULE DISCONNECTED - Disconnect: PRB Module C3313b. - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3038 - Is the resistance less than 5 ohms? Yes GO to V29. No CONNECT all modules. CONNECT the negative battery cable. GO to V69. ------------------------------------------------- V29 VERIFY VEHICLE EQUIPMENT - PAM - Inspect the vehicle for a Parking Aid Module (PAM). - Is the vehicle equipped with a PAM? Yes GO to V30. No GO to V31. ------------------------------------------------- V30 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE PAM DISCONNECTED - Disconnect: PAM C4226 (Expedition) or C4014a (Navigator). - 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 V31. No CONNECT all modules. CONNECT the negative battery cable. GO to V70. ------------------------------------------------- V31 VERIFY VEHICLE EQUIPMENT - LTM - Inspect the vehicle for a Liftgate/Trunk Module (LTM). - Is the vehicle equipped with an LTM? Yes GO to V32. No REPAIR the circuits. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3039 ------------------------------------------------- V32 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE LTM DISCONNECTED - Disconnect: LTM C4174b. - 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 circuits. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No CONNECT all modules. CONNECT the negative battery cable. GO to V71. ------------------------------------------------- V33 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE SJB DISCONNECTED - Disconnect: SJB C2280b. - 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 V58. No GO to V34. ------------------------------------------------- V34 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE IC DISCONNECTED - Disconnect: IC C220. - 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 all modules. CONNECT the negative battery cable. GO to V59. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3040 No GO to V35. ------------------------------------------------- V35 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE ACM DISCONNECTED - Disconnect: ACM C240b. - 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 all modules. CONNECT the negative battery cable. GO to V60. No GO to V36. ------------------------------------------------- V36 VERIFY VEHICLE EQUIPMENT - AUDIO DSP MODULE - Inspect the vehicle for an audio DSP module. - Is the vehicle equipped with an audio DSP module? Yes GO to V37. No GO to V38. ------------------------------------------------- V37 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE AUDIO DSP MODULE DISCONNECTED - Disconnect: Audio DSP Module C2364c. - 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 all modules. CONNECT the negative battery cable. GO to V61. No GO to V38. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3041 ------------------------------------------------- V38 VERIFY VEHICLE EQUIPMENT - HVAC MODULE - Inspect the vehicle for an HVAC module. Is the vehicle equipped with an HVAC module? Yes GO to V39. No GO to V40. ------------------------------------------------- V39 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE HVAC MODULE DISCONNECTED - Disconnect: HVAC Module C228a (EATC) or C2357a (EMTC). - 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 all modules. CONNECT the negative battery cable. GO to V62. No GO to V42. ------------------------------------------------- V40 VERIFY VEHICLE EQUIPMENT - APIM - Inspect the vehicle for an Accessory Protocol Interface Module (APIM). - Is the vehicle equipped with an APIM? Yes GO to V41. No GO to V42. ------------------------------------------------- V41 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3042 - Are the resistances greater than 1,000 ohms? Yes CONNECT all modules. CONNECT the negative battery cable. GO to V63. No GO to V42. ------------------------------------------------- V42 VERIFY VEHICLE EQUIPMENT - AUDIO RCU - Inspect the vehicle for an audio Rear Control Unit (RCU). - Is the vehicle equipped with an audio RCU? Yes GO to V43. No GO to V44. ------------------------------------------------- V43 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE AUDIO RCU DISCONNECTED - Disconnect: Audio RCU C3077. - 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 all modules. CONNECT the negative battery cable. GO to V64. No GO to V44. ------------------------------------------------- V44 VERIFY VEHICLE EQUIPMENT - RETM - Inspect the vehicle for a Rear Entertainment Module (RETM). - Is the vehicle equipped with an RETM? Yes GO to V45. No GO to V46. ------------------------------------------------- V45 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE RETM DISCONNECTED - Disconnect: RETM C949. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3043 VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT all modules. CONNECT the negative battery cable. GO to V65. No GO to V46. ------------------------------------------------- V46 VERIFY VEHICLE EQUIPMENT - DSM - Inspect the vehicle for a Driver Seat Module (DSM). Is the vehicle equipped with a DSM? Yes GO to V47. No GO to V48. ------------------------------------------------- V47 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE DSM DISCONNECTED - Disconnect: DSM C341d. - 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 all modules. CONNECT the negative battery cable. GO to V66. No GO to V48. ------------------------------------------------- V48 VERIFY VEHICLE EQUIPMENT - DCSM - Inspect the vehicle for a Dual Climate Controlled Seat Module (DCSM). - Is the vehicle equipped with a DCSM? Yes GO to V49. No Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3044 GO to V50. ------------------------------------------------V49-V71 Communications Network Pinpoint Tests Pinpoint Test V: 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 - Audio Control Module (ACM) - Accessory Protocol Interface Module (APIM) - Audio Digital Signal Processing (DSP) module (if equipped) - Audio Rear Control Unit (RCU) (if equipped) - Dual Climate Controlled Seat Module (DCSM) (if equipped) - Driver Seat Module (DSM) (if equipped) - HVAC module (if equipped) - Instrument Cluster (IC) - Liftgate/Trunk Module (LTM) (if equipped) - 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) - Data Link Connector (DLC) PINPOINT TEST V: 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: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- V49 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE DCSM DISCONNECTED - Disconnect: DCSM C3265c. - 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 all modules. CONNECT the negative battery cable. GO to V67. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3045 No GO to V50. ------------------------------------------------- V50 VERIFY VEHICLE EQUIPMENT - SDARS MODULE - Inspect the vehicle for a Satellite Digital Audio Receiver System (SDARS) module. - Is the vehicle equipped with a SDARS module? Yes GO to V51. No GO to V52. ------------------------------------------------- V51 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 all modules. CONNECT the negative battery cable. GO to V68. No GO to V52. ------------------------------------------------- V52 VERIFY VEHICLE EQUIPMENT - PRB MODULE - Inspect the vehicle for a PRB module. - Is the vehicle equipped with a PRB module? Yes GO to V53. No GO to V54. ------------------------------------------------- V53 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE PRB MODULE DISCONNECTED - Disconnect: PRB Module C3313b. - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3046 - Are the resistances greater than 1,000 ohms? Yes CONNECT all modules. CONNECT the negative battery cable. GO to V69. No GO to V54. ------------------------------------------------- V54 VERIFY VEHICLE EQUIPMENT - PAM - Inspect the vehicle for a PAM. - Is the vehicle equipped with a PAM? Yes GO to V55. No GO to V56. ------------------------------------------------- V55 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE PAM DISCONNECTED - Disconnect: PAM C4226 (Expedition) or C4014a (Navigator). - 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 all modules. CONNECT the negative battery cable. GO to V70. No GO to V56. ------------------------------------------------- V56 VERIFY VEHICLE EQUIPMENT - LTM - Inspect the vehicle for an LTM. - Is the vehicle equipped with an LTM? Yes GO to V57. No REPAIR the circuit in question. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3047 scan tool. ------------------------------------------------- V57 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE LTM DISCONNECTED - Disconnect: LTM C4174b. - 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 all modules. CONNECT the negative battery cable. GO to V71. 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. ------------------------------------------------- V58 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. ------------------------------------------------- V59 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3048 network test with the scan tool. ------------------------------------------------- V60 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. 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. ------------------------------------------------- V61 CHECK FOR CORRECT AUDIO DSP MODULE OPERATION - Disconnect all the audio DSP module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the audio DSP 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 audio DSP 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. ------------------------------------------------- V62 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. 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. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3049 V63 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. 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. ------------------------------------------------- V64 CHECK FOR CORRECT AUDIO RCU OPERATION - Disconnect the audio RCU connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the audio RCU 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 audio RCU. CLEAR the DTCs. REPEAT the network test with the scan tool. 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 network test with the scan tool. ------------------------------------------------- V65 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. 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 network test with the scan tool. ------------------------------------------------- V66 CHECK FOR CORRECT DSM OPERATION Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3050 - 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. ------------------------------------------------- V67 CHECK FOR CORRECT DCSM OPERATION - Disconnect all the DCSM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the DCSM 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 DCSM. 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. ------------------------------------------------- V68 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. ------------------------------------------------- V69 CHECK FOR CORRECT PRB MODULE OPERATION - Disconnect all the PRB module connectors. - Check for: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3051 - 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. 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. ------------------------------------------------- V70 CHECK FOR CORRECT PAM OPERATION - Disconnect all the PAM connector(s). - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PAM connector(s) 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 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. ------------------------------------------------- V71 CHECK FOR CORRECT LTM OPERATION - Disconnect all the LTM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the LTM 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 LTM. 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 W: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Respond Communications Network Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3052 Pinpoint Tests Pinpoint Test W: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Responding During Network Test Normal Operation The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH). The PCM, the Transmission Control Module (TCM), the ABS module, the Restraints Control Module (RCM), the 4X4 control module (if equipped), the Vehicle Dynamics Module (VDM) (if equipped) and the Instrument Cluster (IC) all communicate with the scan tool using the HS-CAN. 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 - Data Link Connector (DLC) PINPOINT TEST W: INTERMITTENT NO HS-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. ------------------------------------------------- W1 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 W2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- W2 CHECK THE HS-CAN TERMINATION RESISTANCE - 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3053 - Is the resistance between 54 and 66 ohms? Yes GO to W3. No CONNECT the negative battery cable. Go To Pinpoint Test X. See: Pinpoint Test X: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- W3 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 W4. No CONNECT the negative battery cable. Go To Pinpoint Test X. See: Pinpoint Test X: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- W4 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. - Is the voltage greater than 6 volts? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No GO to W5. ------------------------------------------------- W5 CHECK FOR RESTORED COMMUNICATION WITH THE PCM DISABLED Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3054 - Disconnect: Battery Junction Box (BJB) Fuses 35 (40A) and 75 (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 W6. ------------------------------------------------- W6 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE ABS MODULE DISABLED - Disconnect: BJB Fuses 52 (10A), 68 (60A) and 69 (60A). - 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 ABS Module Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to W7. ------------------------------------------------- W7 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE TCM DISABLED - Disconnect: BJB Fuse 26 (15A) and 54 (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 G. See: Pinpoint Test G: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to W8. ------------------------------------------------- W8 VERIFY VEHICLE EQUIPMENT - 4X4 CONTROL MODULE - Inspect the vehicle for a 4X4 control module. - Is the vehicle equipped with a 4X4 control module? Yes GO to W9. No GO to W10. ------------------------------------------------- W9 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE 4X4 CONTROL MODULE DISABLED - Disconnect: BJB Fuse 20 (20A) and 27 (20A). - Enter the following diagnostic mode on the scan tool: Network Test. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3055 - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test E. See: Pinpoint Test E: The 4X4 Control Module Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to W10. ------------------------------------------------- W10 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE IC DISABLED - Disconnect: Smart Junction Box (SJB) Fuse 26 (10A) and 29 (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 C. See: Pinpoint Test C: The Instrument Cluster (IC) Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to W11. ------------------------------------------------- W11 VERIFY VEHICLE EQUIPMENT - VDM - Inspect the vehicle for a VDM. - Is the vehicle equipped with a VDM? Yes GO to W12. No GO to W13. ------------------------------------------------- W12 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE VDM DISABLED - Disconnect: BJB Fuse 53 (10A) and 48 (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 fuses. Go To Pinpoint Test F. See: Pinpoint Test F: The Vehicle Dynamics Module (VDM) Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to W13. ------------------------------------------------- W13 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE RCM DISABLED - Disconnect: SJB Fuse 32 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3056 Yes INSTALL the removed fuse. Go To Pinpoint Test D. See: Pinpoint Test D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool No If the vehicle is equipped with an Accessory Protocol Interface Module (APIM), INSTALL the removed fuses. GO to W14. If the vehicle is not equipped with an APIM, INSTALL the removed fuse. An intermittent fault is not present. Go To Pinpoint Test X. See: Pinpoint Test X: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- W14 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE APIM DISCONNECTED - 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 INSTALL the removed fuses. Go To Pinpoint Test T. See: Pinpoint Test T: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. An intermittent fault is not present. Go To Pinpoint Test X. See: Pinpoint Test X: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------Pinpoint Test X: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding Communications Network Pinpoint Tests Pinpoint Test X: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding Normal Operation The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable. Circuits VDB04 (WH/BU) and VDB05 (WH) provide the network connection to all modules on the HS-CAN. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Data Link Connector (DLC) - 4X4 control module (if equipped) - ABS module - Accessory Protocol Interface Module (APIM) - Instrument Cluster (IC) - PCM - Restraints Control Module (RCM) - Transmission Control Module (TCM) - Vehicle Dynamics Module (VDM) (if equipped) PINPOINT TEST X: 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3057 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. ------------------------------------------------- X1 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 X2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- X2 CHECK THE HS-CAN TERMINATION RESISTANCE - 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 X3. No GO to X5. ------------------------------------------------- X3 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3058 GO to X4. No GO to X19. ------------------------------------------------- X4 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. - 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. VERIFY the scan tool operation on a substitute vehicle, and REPEAT the network test on the suspect vehicle. ------------------------------------------------- X5 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 X6. No GO to X9. ------------------------------------------------- X6 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3059 - Is the resistance between 108 and 132 ohms? Yes GO to X7. No GO to X8. ------------------------------------------------- X7 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM AND THE DLC FOR AN OPEN - Measure the resistance between the PCM C175b-59, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the PCM C175b-43, 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 X27. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- X8 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 Data Link Connector (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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3060 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to X33. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- X9 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? Yes GO to X11. No GO to X10. ------------------------------------------------- X10 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM AND THE DLC FOR AN OPEN - Disconnect: PCM C175b. - Measure the resistance between the PCM C175b-59, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the PCM C175b-43, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3061 - Are the resistances less than 5 ohms? Yes The Controller Area Network (CAN) has tested within specifications. CONNECT the negative battery cable. VERIFY the scan tool operation on a substitute vehicle, and REPEAT the network test on the suspect vehicle. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- X11 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 If the vehicle is equipped with a Vehicle Dynamics Module (VDM), GO to X12. If the vehicle is not equipped with a VDM, GO to X13. No CONNECT the negative battery cable. GO to X27. ------------------------------------------------- X12 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE VDM DISCONNECTED - Disconnect: VDM C2131a. - 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 X13. No Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3062 CONNECT the negative battery cable. GO to X28. ------------------------------------------------- X13 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE ABS MODULE DISCONNECTED - Disconnect: ABS Module C135. - 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 4X4 control module, GO to X14. If the vehicle is not equipped with a 4X4 control module, GO to X15. No CONNECT the negative battery cable. GO to X29. ------------------------------------------------- X14 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 X15. No CONNECT the negative battery cable. GO to X30. ------------------------------------------------- X15 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? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3063 Yes If the vehicle is equipped with an Accessory Protocol Interface Module (APIM), GO to X16. If the vehicle is not equipped with an APIM, GO to X17. No CONNECT the negative battery cable. GO to X31. ------------------------------------------------- X16 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 X17. No CONNECT the negative battery cable. GO to X32. ------------------------------------------------- X17 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 If the vehicle is equipped with a Transmission Control Module (TCM), GO to X18. If the vehicle is not equipped with a TCM, 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 X33. ------------------------------------------------- X18 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE TCM DISCONNECTED - Disconnect: TCM C1548. - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3064 - 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 X34. ------------------------------------------------- X19 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. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to X27. No If the vehicle is equipped with a Vehicle Dynamics Module (VDM), GO to X20. If the vehicle is not equipped with a VDM, GO to X21. ------------------------------------------------- X20 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE VDM DISCONNECTED - Disconnect: VDM C2131a. - 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. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to X28. No GO to X21. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3065 X21 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE ABS MODULE DISCONNECTED - Disconnect: ABS Module C135. - 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. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to X29. No If the vehicle is equipped with a 4X4 control module, GO to X22. If the vehicle is not equipped with a 4X4 control module, GO to X23. ------------------------------------------------- X22 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. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to X30. No GO to X23. ------------------------------------------------- X23 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. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to X31. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3066 No If the vehicle is equipped with an Accessory Protocol Interface Module (APIM), GO to X24. If the vehicle is not equipped with an APIM, GO to X25. ------------------------------------------------- X24 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. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to X32. No GO to X25. ------------------------------------------------- X25 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. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to X33. No If the vehicle is equipped with a Transmission Control Module (TCM), GO to X26. If the vehicle is not equipped with a TCM, REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- X26 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE TCM DISCONNECTED - Disconnect: TCM C1548. - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3067 - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to X34. No REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- X27 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. 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. ------------------------------------------------- X28 CHECK FOR CORRECT VDM OPERATION - Disconnect all the VDM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the VDM 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 VDM. 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. ------------------------------------------------- X29 CHECK FOR CORRECT ABS MODULE OPERATION - Disconnect the ABS module connector. - Check for: corrosion - damaged pins - pushed-out pins Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3068 - 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. ------------------------------------------------- X30 CHECK FOR CORRECT 4X4 CONTROL MODULE OPERATION - Disconnect all 4X4 control module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all 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. 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. ------------------------------------------------- X31 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. 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. ------------------------------------------------- X32 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? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3069 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. CONNECT all modules. The concern may have been caused by a loose or corroded connector. REPEAT the network test with the scan tool. ------------------------------------------------- X33 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. - 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. ------------------------------------------------- X34 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. ------------------------------------------------Pinpoint Test Y: No Power To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test Y: No Power 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3070 The scan tool is connected to the Data Link Connector (DLC) to communicate with the High Speed Controller Area Network (HS-CAN) and the Medium Speed Controller Area Network (MS-CAN) communications network. Voltage for the scan tool is provided by circuit SBP20 (GN/RD). Ground is provided by circuits GD113 (BK/YE) and GD138 (BK/WH). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Data Link Connector (DLC) - Scan tool PINPOINT TEST Y: 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. ------------------------------------------------- Y1 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 Y2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Y2 CHECK THE DLC VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Measure the voltage between the DLC C251-16, circuit SBP20 (GN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to Y3. No VERIFY the Smart Junction Box (SJB) fuse 20 (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. REPEAT the network test with the scan tool. ------------------------------------------------- Y3 CHECK THE DLC GROUND CIRCUITS FOR AN OPEN Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3071 - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-4, circuit GD138 (BK/WH), harness side and ground; and between the DLC C251-5, circuit GD113 (BK/YE), 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3072 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3073 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3074 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3079 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3082 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3083 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3084 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3088 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3089 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3103 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3104 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3105 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3106 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3107 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3110 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3111 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3112 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) > Page 3115 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3118 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. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. - Apply penetrating lubricant to the HO2S to assist in removal. Installation 1. Install the HO2S. - Apply a light coat of high temperature nickel anti-seize lubricant to the HO2S threads prior to installation. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft). 2. Connect the HO2S electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3119 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 3. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. - Apply penetrating lubricant to the CMS to assist in removal. Installation 1. Install the CMS. - Apply a light coat of high temperature nickel anti-seize lubricant to the CMS threads prior to installation. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft). 2. Connect the CMS electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3123 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3124 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3127 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3135 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3136 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3137 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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts Engine Control Module: Customer Interest Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 3146 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 3147 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3152 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3153 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 3159 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 3160 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3165 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3166 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3167 Engine Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3168 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3169 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3170 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3171 Engine Control Module: Diagrams C175B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3172 C175B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3173 C175B Part 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3174 C175E Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3175 C175E Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3176 C175E Part 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3177 C175T Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3178 C175T Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3181 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3182 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) Removal and Installation 1. NOTE: Refer to Computers and Control Systems Information for correct Vehicle Communication Module (VCM) hook-up procedure. If servicing the PCM, connect the scan tool to the vehicle. Allow the scan tool to identify the vehicle and obtain configuration data. - All programmable module information will automatically be retrieved by the VCM. 2. Disconnect the battery ground cable. 3. Disconnect the 3 PCM electrical connectors. 4. Remove the 2 stud bolts and the PCM. - To install, tighten to 9 Nm (80 lb-in). 5. NOTE: If the Instrument Cluster (IC) or the PCM is being replaced (or both), the parameters must be reset in both modules or the vehicle will experience a Passive Anti-Theft System (PATS) no-start. This will occur even if the vehicle is not equipped with PATS. To install, reverse the removal procedure. 6. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3186 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3187 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3192 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3193 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3194 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3198 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3199 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls Air Flow Meter/Sensor: Description and Operation Electronic Engine Controls Electronic Engine Controls Mass Air Flow (MAF) Sensor The MAF sensor: - sends the PCM a signal indicating mass airflow rate of air entering the engine. - incorporates the Intake Air Temperature (IAT) sensor. For removal and installation, refer to Mass Air Flow (MAF) Sensor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 3202 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 3203 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation > Page 3204 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 2 > Page 3209 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3212 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3213 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3214 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation LH Camshaft Position (CMP) sensor 1. Remove the Air Cleaner (ACL) outlet pipe. All CMP sensors 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3224 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3225 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3226 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt from the A/C compressor pulley. 3. Disconnect the A/C compressor electrical connector. 4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3227 7. To install, reverse the removal procedure. 8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3231 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3232 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3233 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor and discard. - To install, tighten to 10 Nm (89 lb-in). - Coat the new CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3239 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3240 Fuel Level Sensor: Service and Repair Fuel Pump Module Fuel Pump Module 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3241 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. All fuel tanks 1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank. 127L (33.5 gal) fuel tank 2. Remove the 4 nuts and the Fuel Pump (FP) module cover. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the return fuel tube-to-FP module quick connect coupling. All fuel tanks 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. 5. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring. 106L (28 gal) fuel tank 6. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3242 Remove the FP and FP O-ring seal. If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange. - Discard the FP O-ring seal. 127L (33.5 gal) fuel tank 7. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: Note the location of the FP alignment tabs. Remove the FP module assembly. Remove and discard the O-ring seal. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3246 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3247 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3248 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor 106L (28 Gal) Fuel Tank 125L (33 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 3251 Removal and Installation All fuel tanks 1. Remove the fuel tank. 106L (28 gal) fuel tank 2. Disconnect the fuel supply tube-to-heat shield pushpin retainer. 125L (33 gal) fuel tank 3. Remove the fuel tank heat shield retainer(s). All fuel tanks 4. Remove the fuel tank heat shield. 5. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-fuel vapor/grade vent valves quick connect couplings. 6. Disconnect the FTP sensor and vapor tube assembly-to-fuel pump module quick connect coupling. 7. Remove the FTP sensor and vapor tube assembly from the fuel tank. 8. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 3252 Fuel Tank Pressure Sensor: Service and Repair Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair > Fuel Tank Pressure Sensor > Page 3253 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3257 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3258 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3259 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3264 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3267 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3268 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3269 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3280 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3281 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3282 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3283 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3284 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3287 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3288 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3289 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3292 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3295 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. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. - Apply penetrating lubricant to the HO2S to assist in removal. Installation 1. Install the HO2S. - Apply a light coat of high temperature nickel anti-seize lubricant to the HO2S threads prior to installation. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft). 2. Connect the HO2S electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3296 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector. 3. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. - Apply penetrating lubricant to the CMS to assist in removal. Installation 1. Install the CMS. - Apply a light coat of high temperature nickel anti-seize lubricant to the CMS threads prior to installation. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft). 2. Connect the CMS electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3300 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3301 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3304 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3311 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3314 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3315 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal 1. Remove the Throttle Body (TB). 2. 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 ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 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 1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB. 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). 2. Install the TB. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3320 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3324 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3327 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3328 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal 1. Remove the Throttle Body (TB). 2. 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 ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 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 1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB. 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). 2. Install the TB. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise Variable Valve Timing Actuator: Customer Interest Engine - Low Frequency Hot Idle Knocking Noise TSB 10-18-4 09/27/10 LOW FREQUENCY ENGINE KNOCKING NOISE AT HOT IDLE FORD: 2009-2010 Expedition, F-150, F-250, F-350 LINCOLN: 2009-2010 Navigator This article supersedes TSB 09-23-7 to update the vehicle model lines, Service Procedure and Service Labor Time Standards. ISSUE Some 2009-2010 F-150 and F-Super Duty vehicles equipped with a 4.6L 3V or 5.4L 3V engine, Expedition and Navigator vehicles may exhibit a low frequency knocking noise from the engine at hot idle only. The noise is predominately heard from the right front wheel well area and/or the right hand (RH) engine cam cover. This noise may be generated from the RH variable camshaft timing (VCT) phaser assembly. This procedure was created to diagnose the RH VCT phaser assembly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The Integrated Diagnostic System (IDS) tests were developed specifically for the vehicles and Power Control Module (PCM) strategies for these vehicles. Per Workshop Manual (WSM), Powertrain Controls and Emissions Diagnostics (PC/ED) and Scheduled Maintenance Guide, review customer service history for use of any aftermarket oil filters. 1. Check for possible diagnostic trouble codes (DTCs). a. No DTCs present, proceed to Step 2. b. If DTCs are present, do not continue with this procedure and refer to the PC/ED manual for diagnostics. 2. Engine must be at full operating temperature over 190 °F (88 °C) cylinder head temperature (CHT). 3. Connect IDS diagnostics tool and verify software version is at the latest level (63 or later required). 4. Begin a new vehicle session. 5. Open Tool Box selection. 6. Open Data Logger. 7. Select Powertrain Engine. 8. Select PCM Data Logger. 9. Clear the preselected items by clicking the eraser icon button. 10. Select variable cam timing desired angle number (VCLDSD). 11. Go to live display and press the tick mark. 12. Make sure the parameter identification (PID) is highlighted with the dark lines above and below the data being displayed. 13. Press number symbol: (output state control mode) of the VCT_DSD number PID. 14. Press the Control Item Activate (finger on the button) icon to enable manual control of the PID. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise > Page 3337 15. Use the plus button to command to 4 degrees. (One click is equal to 1 degree) When commanding the advance, both banks will normally adjust. 16. Listen carefully to the low frequency knock noise while commanding the VCT_DSD from 0 to 4 degrees. Some higher frequency clatter is normal at or above the 5 degree advance. What is being pursued is for the level of the low frequency knock noise to be noticeably reduced when advanced from 4 to 5 degrees. a. If noise level is noticeably reduced as the VCT desired angle is commanded from 3 to 4 degrees, the noise source is the RH VCT phaser assembly. Proceed to Step 17. b. If the low frequency knock noise is not noticeably reduced at 4 degrees, refer to WSM, Section 303-00 for engine noise diagnostics. 17. Due to normal engine dynamics, the VCT phaser knock noise is produced by the RH VCT phaser assembly. Replace only the RH VCT phaser assembly. Refer to WSM, Section 303-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT:Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101804A 2009-2010 Expedition, 2.3 Hrs Navigator 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150 4.6L 3V: 1.8 Hrs. Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150, F-Super 2.1 Hrs. Duty 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6A257 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Low Frequency Hot Idle Knocking Noise TSB 10-18-4 09/27/10 LOW FREQUENCY ENGINE KNOCKING NOISE AT HOT IDLE FORD: 2009-2010 Expedition, F-150, F-250, F-350 LINCOLN: 2009-2010 Navigator This article supersedes TSB 09-23-7 to update the vehicle model lines, Service Procedure and Service Labor Time Standards. ISSUE Some 2009-2010 F-150 and F-Super Duty vehicles equipped with a 4.6L 3V or 5.4L 3V engine, Expedition and Navigator vehicles may exhibit a low frequency knocking noise from the engine at hot idle only. The noise is predominately heard from the right front wheel well area and/or the right hand (RH) engine cam cover. This noise may be generated from the RH variable camshaft timing (VCT) phaser assembly. This procedure was created to diagnose the RH VCT phaser assembly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The Integrated Diagnostic System (IDS) tests were developed specifically for the vehicles and Power Control Module (PCM) strategies for these vehicles. Per Workshop Manual (WSM), Powertrain Controls and Emissions Diagnostics (PC/ED) and Scheduled Maintenance Guide, review customer service history for use of any aftermarket oil filters. 1. Check for possible diagnostic trouble codes (DTCs). a. No DTCs present, proceed to Step 2. b. If DTCs are present, do not continue with this procedure and refer to the PC/ED manual for diagnostics. 2. Engine must be at full operating temperature over 190 °F (88 °C) cylinder head temperature (CHT). 3. Connect IDS diagnostics tool and verify software version is at the latest level (63 or later required). 4. Begin a new vehicle session. 5. Open Tool Box selection. 6. Open Data Logger. 7. Select Powertrain Engine. 8. Select PCM Data Logger. 9. Clear the preselected items by clicking the eraser icon button. 10. Select variable cam timing desired angle number (VCLDSD). 11. Go to live display and press the tick mark. 12. Make sure the parameter identification (PID) is highlighted with the dark lines above and below the data being displayed. 13. Press number symbol: (output state control mode) of the VCT_DSD number PID. 14. Press the Control Item Activate (finger on the button) icon to enable manual control of the PID. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: > 10-18-4 > Sep > 10 > Engine - Low Frequency Hot Idle Knocking Noise > Page 3343 15. Use the plus button to command to 4 degrees. (One click is equal to 1 degree) When commanding the advance, both banks will normally adjust. 16. Listen carefully to the low frequency knock noise while commanding the VCT_DSD from 0 to 4 degrees. Some higher frequency clatter is normal at or above the 5 degree advance. What is being pursued is for the level of the low frequency knock noise to be noticeably reduced when advanced from 4 to 5 degrees. a. If noise level is noticeably reduced as the VCT desired angle is commanded from 3 to 4 degrees, the noise source is the RH VCT phaser assembly. Proceed to Step 17. b. If the low frequency knock noise is not noticeably reduced at 4 degrees, refer to WSM, Section 303-00 for engine noise diagnostics. 17. Due to normal engine dynamics, the VCT phaser knock noise is produced by the RH VCT phaser assembly. Replace only the RH VCT phaser assembly. Refer to WSM, Section 303-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT:Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 101804A 2009-2010 Expedition, 2.3 Hrs Navigator 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150 4.6L 3V: 1.8 Hrs. Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 101804A 2009-2010 F-150, F-Super 2.1 Hrs. Duty 5.4L 3V: Replace The RH VCT Phaser Assembly Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 6A257 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 3344 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 3345 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Variable Camshaft Timing (VCT) Solenoid 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Variable Camshaft Timing (VCT) Solenoid 1 > Page 3350 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Variable Camshaft Timing (VCT) Solenoid 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Variable Camshaft Timing (VCT) Solenoid 1 > Page 3353 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Page 3354 Variable Valve Timing Solenoid: Service and Repair Variable Camshaft Timing (VCT) Oil Control Solenoid NOTE: LH shown, RH similar. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 3359 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3374 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3375 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3376 Catalytic Converter: Service and Repair Exhaust System - Exploded View Expedition and Navigator NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. Expedition EL and Navigator L NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3377 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set Canister Purge Control Valve: Customer Interest Emissions - Rough Running/Hard Start/DTC's Set TSB 11-1-5 01/25/11 RUNS ROUGH, HARD START AFTER REFUELING, AUDIBLE CLICKING NOISE UNDER HOOD, AND/OR DTCS P0316, P144A, P1450, PO17X, P044X, P045X, BUILT ON OR BEFORE 11/1/2010 FORD: 2010-2011 Fusion 2009-2010 F-150 2009-2011 E-Series, Escape, Expedition 2011 F-250, F-350 LINCOLN: 2011 MKZ 2009-2011 Navigator MERCURY: 2010-2011 Milan 2009-2011 Mariner ISSUE Some 2009-2010 F-150, 2009-2011 Expedition, Navigator, E-Series, Escape Hybrid, Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid and F-Super Duty 250/350 equipped with a 6.2L engine and built on or before 11/1/2010, may exhibit a running rough concern, hard start after refueling, audible clicking noise under the hood and/or diagnostic trouble codes (DTCs) P0316, P144A, P1450, PO17X, P044X, P045X. ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE Replace the Evaporative Emission Canister Purge Valve. Refer to Workshop Manual, Section 303-13. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Canister Purge Control Valve: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set > Page 3387 OPERATION DESCRIPTION TIME 110105A 2009-2011 Expedition, 0.6 Hr. Navigator, And Econoline 2009-2010 F-150: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Escape Hybrid, 0.7 Hr. Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid, And 2011 F-Super Duty 6.2L: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Econoline: 0.9 Hr. Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 9C915 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set Canister Purge Control Valve: All Technical Service Bulletins Emissions - Rough Running/Hard Start/DTC's Set TSB 11-1-5 01/25/11 RUNS ROUGH, HARD START AFTER REFUELING, AUDIBLE CLICKING NOISE UNDER HOOD, AND/OR DTCS P0316, P144A, P1450, PO17X, P044X, P045X, BUILT ON OR BEFORE 11/1/2010 FORD: 2010-2011 Fusion 2009-2010 F-150 2009-2011 E-Series, Escape, Expedition 2011 F-250, F-350 LINCOLN: 2011 MKZ 2009-2011 Navigator MERCURY: 2010-2011 Milan 2009-2011 Mariner ISSUE Some 2009-2010 F-150, 2009-2011 Expedition, Navigator, E-Series, Escape Hybrid, Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid and F-Super Duty 250/350 equipped with a 6.2L engine and built on or before 11/1/2010, may exhibit a running rough concern, hard start after refueling, audible clicking noise under the hood and/or diagnostic trouble codes (DTCs) P0316, P144A, P1450, PO17X, P044X, P045X. ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE Replace the Evaporative Emission Canister Purge Valve. Refer to Workshop Manual, Section 303-13. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Canister Purge Control Valve: > 11-1-5 > Jan > 11 > Emissions - Rough Running/Hard Start/DTC's Set > Page 3393 OPERATION DESCRIPTION TIME 110105A 2009-2011 Expedition, 0.6 Hr. Navigator, And Econoline 2009-2010 F-150: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Escape Hybrid, 0.7 Hr. Mariner Hybrid, 2010-2011 Fusion Hybrid, Milan Hybrid, 2011 MKZ Hybrid, And 2011 F-Super Duty 6.2L: Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) 110105A 2009-2011 Econoline: 0.9 Hr. Check DTCs, And Replace The Evaporative Emission Canister Purge Valve (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 9C915 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Page 3394 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Technical Service Bulletins > Page 3395 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View Canister Purge Control Valve: Service and Repair Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View > Page 3398 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View > Page 3399 Canister Purge Control Valve: Service and Repair Evaporative Emission Canister Purge Valve 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. Disconnect the battery ground cable. 2. Disconnect the Evaporative Emission (EVAP) canister purge valve and hose electrical connector. 3. Disconnect EVAP canister purge valve hose-to-intake manifold quick connect coupling. 4. Disconnect the EVAP canister-to-EVAP canister purge valve and hose assembly vapor tube quick connect coupling. 5. Slide the EVAP canister purge valve and hose assembly off the bracket. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View Evaporative Canister Filter: Service and Repair Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View > Page 3404 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission Control Canister: Service and Repair Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View > Page 3409 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View > Page 3410 Evaporative Emission Control Canister: Service and Repair Evaporative Emission Canister Evaporative Emission Canister 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: The Evaporative Emission (EVAP) canister vent solenoid and dust separator are an assembly. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the EVAP canister vent solenoid electrical jumper from the wiring harness. 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-EVAP canister quick connect coupling. 5. Disconnect the EVAP canister purge valve vapor tube-to-EVAP canister quick connect coupling. 6. Disconnect the fresh air tube-to-canister vent solenoid and dust separator assembly quick connect coupling. 7. Remove the EVAP canister assembly bracket-to-frame rail bolt in the rear. - To install, tighten to 20 Nm (177 lb-in). 8. Remove the EVAP canister assembly bracket-to-frame rail bolt in the front. - To install, tighten to 20 Nm (177 lb-in). 9. Remove the EVAP canister assembly bracket and exhaust Y-pipe dual catalytic converter heat shield-to-transmission crossmember bolt and remove the EVAP canister assembly from the vehicle. To install, tighten to 20 Nm (177 lb-in). 10. Disconnect the EVAP canister vent solenoid electrical connector. 11. Remove the 5 EVAP canister-to-EVAP canister assembly bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 12. Remove the EVAP canister assembly from the EVAP canister assembly brackets. 13. Remove the canister vent solenoid and dust separator assembly from the EVAP canister. 14. NOTE: Inspect the EVAP canister heat shield and if damaged, install a new EVAP canister heat shield. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3417 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3418 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View Leak Detection Valve: Service and Repair Evaporative Emission (EVAP) System Components Exploded View Evaporative Emission (EVAP) System Components - Exploded View Evaporative Emission (EVAP) Canister Assembly NOTE: 106L (28 gal) fuel tank vapor tubes shown, 125L (33 gal) similar. EVAP Canister, Vent Solenoid and Dust Separator and Brackets Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View > Page 3421 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Evaporative Emission (EVAP) System Components - Exploded View > Page 3422 Leak Detection Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Evaporative Emission Canister Vent Solenoid 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: The Evaporative Emission (EVAP) canister vent solenoid and dust separator are an assembly. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the EVAP canister vent solenoid electrical jumper from the wiring harness. 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-EVAP canister quick connect coupling. 5. Disconnect the EVAP canister purge valve vapor tube-to-EVAP canister quick connect coupling. 6. Disconnect the fresh air tube-to-canister vent solenoid and dust separator assembly quick connect coupling. 7. Remove the EVAP canister assembly bracket-to-frame rail bolt in the rear. - To install, tighten to 20 Nm (177 lb-in). 8. Remove the EVAP canister assembly bracket-to-frame rail bolt in the front. - To install, tighten to 20 Nm (177 lb-in). 9. Remove the EVAP canister assembly bracket and exhaust Y-pipe dual catalytic converter heat shield-to-transmission crossmember bolt and remove the EVAP canister assembly from the vehicle. To install, tighten to 20 Nm (177 lb-in). 10. Disconnect the EVAP canister vent solenoid electrical connector. 11. Remove the 2 EVAP canister-to-EVAP canister assembly bracket bolts in the front of the canister. - To install, tighten to 6 Nm (53 lb-in). 12. Remove the canister vent solenoid and dust separator assembly from the EVAP canister. 13. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3434 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3435 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Heater > Component Information > Service and Repair PCV Heater: Service and Repair Positive Crankcase Ventilation (PCV) Heater Element Air Intake Resonator and PCV Tube Heated PCV Heater Element Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Heater > Component Information > Service and Repair > Page 3443 Removal 1. Release the clamp and remove the bolt and the air intake resonator assembly. 2. Disconnect the quick connect couplings and remove the PCV tube. 3. Disconnect the PCV heater element electrical connector. 4. Remove the 2 bolts and the PCV heater element. - Discard the O-ring seal. Installation 1. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, install the PCV heater element and the 2 bolts. - Tighten to 6 Nm (53 lb-in). 2. Connect the PCV heater element electrical connector. 3. Position the PCV tube and connect the quick connect couplings. 4. Position the air intake resonator assembly, install the bolt and the clamp. - Tighten to 10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Engine running..................................................................................................................................... ..............................................379-414 kPa (55-60 psi) Key ON Engine OFF (KOEO)......................... ..................................................................................................................................379-414 kPa (55-60 psi) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3455 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. Remove the cap from the fuel pressure relief valve located on the fuel rail. 2. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 3. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 4. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place 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. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3456 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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: 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. 1. Disconnect the battery ground cable. 2. Remove the cap from the fuel pressure relief valve located on the fuel rail. 3. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 4. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the Fuel Pressure Test Kit and relieve the fuel pressure. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 3460 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 695 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Description and Operation > Adjustable Pedals - Without Memory Feature Accelerator Pedal: Description and Operation Adjustable Pedals - Without Memory Feature Adjustable Pedals Adjustable brake and accelerator pedals are available as an optional feature on this vehicle. The brake pedal position can be changed in phase with the accelerator pedal to increase driver comfort. Two different adjustable pedal systems are available; one that is connected to the memory feature option and one that is not connected to the memory feature option. Without Memory Feature Adjustable brake pedals without memory feature consist of the following components: - Adjustable brake pedal and bracket - Adjustable accelerator pedal and bracket, refer to Throttle Cable/Linkage. - Adjustable pedal switch - Adjustable pedal motor - Adjustable pedal cables The pedals are adjusted through the use of a rocker switch mounted on the instrument panel. When the switch is pressed, voltage is sent to the motor which spins a cable that is attached to the adjustable brake pedal. As the cable spins, the pedals move either forward (away from the driver) or rearward (toward the driver) depending on how the switch is pressed. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Description and Operation > Adjustable Pedals - Without Memory Feature > Page 3468 Accelerator Pedal: Description and Operation Adjustable Pedals - With Memory Feature Adjustable Pedals Adjustable brake and accelerator pedals are available as an optional feature on this vehicle. The brake pedal position can be changed in phase with the accelerator pedal to increase driver comfort. Two different adjustable pedal systems are available; one that is connected to the memory feature option and one that is not connected to the memory feature option. With Memory Feature Adjustable brake and accelerator pedals are available as an optional feature on this vehicle. The brake pedal position can be changed in phase with the accelerator pedal to increase driver comfort. Two different adjustable pedal systems are available; one that is connected to the memory feature option and one that is not connected to the memory feature option. Adjustable brake pedals with memory feature consist of the following components: - Driver Seat Module (DSM), refer to Seats - Memory SET switch, refer to Seats - Remote Keyless Entry (RKE) transmitter, refer to Locks - Adjustable brake pedal and bracket - Adjustable accelerator pedal and bracket, refer to Throttle Cable/Linkage - Adjustable pedal switch - Adjustable pedal motor - Adjustable pedal cables The pedals are adjusted through the use of a rocker switch mounted on the instrument panel, the memory SET switch mounted on the seat trim panel or the door trim panel or the RKE transmitter. When the switch is pressed or the transmitter is activated, a voltage signal is sent to the DSM. The DSM then sends voltage to the adjustable pedal motor which spins a cable that is attached to the adjustable brake pedal. As the cable spins, the pedals move either forward (away from the driver) or rearward (toward the driver) depending on how the switch is pressed and/or current pedal position. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Position (APP) sensor electrical connector. 2. Remove the 3 bolts and the accelerator pedal assembly. - To install, tighten to 25 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed > Page 3471 Accelerator Pedal: Service and Repair Accelerator Pedal - Adjustable Accelerator Pedal - Adjustable Removal and Installation NOTE: The brake pedal and the accelerator pedal must be in the same position when installing a new cable or a new pedal. The pedals must be in the all the way forward or the all the way rearward position. 1. Disconnect the Accelerator Pedal Position (APP) sensor electrical connector. 2. Remove the 3 bolts and the accelerator pedal assembly. - To install, tighten to 12 Nm (106 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3475 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3476 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3477 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 Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3483 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element Removal and Installation 1. Disconnect the Air Cleaner (ACL) outlet pipe from the ACL cover. - To install, tighten the clamps to 4 Nm (35 lb-in). 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Release the retaining clips and position the ACL cover aside. 4. Remove the ACL element. 5. NOTE: The ACL element must be fully seated into the ACL housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3487 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3488 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls Air Flow Meter/Sensor: Description and Operation Electronic Engine Controls Electronic Engine Controls Mass Air Flow (MAF) Sensor The MAF sensor: - sends the PCM a signal indicating mass airflow rate of air entering the engine. - incorporates the Intake Air Temperature (IAT) sensor. For removal and installation, refer to Mass Air Flow (MAF) Sensor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 3491 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 3492 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation > Page 3493 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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. 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: 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. 1. Disconnect the battery ground cable. 2. Remove the cap from the fuel pressure relief valve located on the fuel rail. 3. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 4. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the fuel system. Place fuel in a suitable container. Open the manual valve on the Fuel Pressure Test Kit and relieve the fuel pressure. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3501 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3506 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Flow and Leakage ...................................................................................... Refer to Pinpoint Test HC12 at Computers and Control Systems. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3509 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3510 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3511 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3512 Fuel Injector: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3513 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3514 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3515 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3516 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3517 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3518 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3519 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3520 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Air Cleaner (ACL) Outlet Pipe-To-Throttle Body (TB) Adapter, Air Intake Resonator and PCV Tube Fuel Rail and Fuel Injectors Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Page 3523 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings Fuel Line Coupler: Service and Repair Vapor Tube Fittings Vapor Tube Fittings Disconnect 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: 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. 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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 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 can occur. Always install blanking plugs to any open orifices or tubes. 1. Disconnect the battery ground cable. 2. 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 vapor tube fitting. - Push the connector toward the tube or fitting to release pressure. - Press the quick connect fitting button and pull the fuel tube to disconnect. Connect 1. Inspect and clean both quick connect 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: Apply clean engine oil to the end of the tube or fitting before connecting. Connect the vapor tube fitting. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3528 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3529 Fuel Line Coupler: Service and Repair Quick Connect Coupling Quick Connect Coupling 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: 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. 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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 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 can occur. Always install blanking plugs to any open orifices or tubes. 1. 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 quick connect coupling. - Push the connector toward the tube to release pressure. - Push the release tab clockwise. - Disconnect the quick connect coupling. Connect - Type I 1. Inspect and clean both quick connect coupling ends. 2. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 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 the end of the tube and the quick connect coupling O-ring seals. Connect the quick connect coupling. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3530 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 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: 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: 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. 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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 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 can occur. Always install blanking plugs to any open orifices or tubes. 1. If servicing a liquid fuel tube quick connect coupling, 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. NOTE: When reusing liquid or vapor tube quick connect couplings, make sure to use compressed air to remove any foreign material from the tube. Apply clean engine oil to the end of the tube before connecting the quick connect coupling. Spread the legs of the retainer clip and pull it to the outward position in the quick connect coupling. 4. Depress the retainer clip and disconnect the quick connect coupling from the tube. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3531 Connect - Type II 1. Install the quick connect coupling onto the tube until fully seated. 2. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick connect coupling. Press the retainer clip into the quick connect coupling body until flush and the legs are locked in place. 3. Connect the battery ground cable. Disconnect - Type III 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: 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: 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. 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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 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 can occur. Always install blanking plugs to any open orifices or tubes. 1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3532 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 III 1. Inspect and clean both quick connect 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: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. Install the quick connect coupling onto the tube until it is fully seated. 3. Connect the battery ground cable. 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: 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: 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. 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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 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 can occur. Always install blanking plugs to any open orifices or tubes. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3533 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 2 fuel tube quick connect coupling buttons and pull the fuel tube to disconnect. Connect - Type IV 1. Inspect and clean both quick connect 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: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. Install the quick connect coupling onto the tube until it is fully seated. 3. Connect the battery ground cable. Disconnect - Type V 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: 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. 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: 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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3534 observed when working with these components or component damage can occur. Always install blanking plugs to any open orifices or tubes. 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. Depress the legs of the retainer clip and position the clip to the outward position. 4. Disconnect the quick connect coupling from the fuel tube. Connect - Type V 1. Inspect and clean both quick connect coupling ends. 2. NOTE: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. Install the quick connect coupling onto the fuel tube until fully seated. 3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: Make sure the retainer clip is fully seated and locked onto the fuel tube by pulling on the quick connect coupling. Press the retainer clip into the quick connect coupling body until flush and the legs are locked in place. 4. Connect the battery ground cable. Disconnect - Type VI WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3535 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: 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. 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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 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 can occur. Always install blanking plugs to any open orifices or tubes. 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. 5. Separate the quick connect coupling. Connect - Type VI 1. Inspect and clean both quick connect 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: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3536 Connect the tube into the quick connect coupling. 3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 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 into place. 5. Connect the battery ground cable. Disconnect - Type VII 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: 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. 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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 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 can occur. Always install blanking plugs to any open orifices or tubes. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3537 Squeeze the quick connect coupling retainer locking tabs to release the locking mechanism. 4. Push the locking mechanism outward to release the tube. 5. Remove the quick connect coupling from the tube. Connect - Type VII 1. Inspect and clean both quick connect 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: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. Install the quick connect coupling onto the tube. 3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. Depress the quick connect coupling locking mechanism into the lock position. 4. Visually inspect and verify that the locking mechanism is flush with the quick connect coupling housing and that the locking tabs are securely fastened. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 3538 5. Pull on the quick connect coupling and the tube to make sure it is securely fastened. 6. Connect the battery ground cable. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Engine running..................................................................................................................................... ..............................................379-414 kPa (55-60 psi) Key ON Engine OFF (KOEO)......................... ..................................................................................................................................379-414 kPa (55-60 psi) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3546 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. Remove the cap from the fuel pressure relief valve located on the fuel rail. 2. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve. 3. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 4. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place 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. 5. NOTE: It may take more than one key cycle to pressurize the fuel system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3547 Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Service and Repair Fuel Pump Control Unit: Service and Repair Fuel Pump Control Module Removal and Installation 1. Disconnect the fuel pump control module electrical connector. 2. Remove the 2 bolts and the fuel pump control module. - To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3554 Fuel Pump Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3555 Ford Expedition 2wd Workshop Manual (V8-5.4L (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. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. 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. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the Air Cleaner (ACL) outlet pipe. 4. Disconnect the crankcase ventilation tube quick connect coupling from the ACL outlet pipe-to-Throttle Body (TB) adapter. 5. Release the clamp and remove the bolt and the air intake resonator assembly. - To install, tighten to 10 Nm (89 lb-in). 6. Remove the 3 ACL outlet pipe-to-TB adapter bolts. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the ACL outlet pipe-to-TB adapter. 8. Disconnect the Electronic Throttle Control (ETC) electrical connector. 9. Disconnect the Throttle Position (TP) sensor electrical connector. 10. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the intake manifold. 11. Disconnect the heated PCV intake fitting electrical connector. 12. Disconnect the fuel tube quick connect coupling. 13. Disconnect the 8 fuel injector electrical connectors. 14. Remove the 4 fuel rail bolts and the fuel rail and injectors as an assembly. - To install, tighten to 10 Nm (89 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 3560 15. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation. Remove the fuel injector-to-fuel rail locks and separate the 8 fuel injectors from the fuel rail. - Discard the upper and lower fuel injector O-ring seals. 16. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 3561 Fuel Rail: Service and Repair Fuel Rail And Fuel Injector - Exploded View Fuel Rail and Fuel Injector - Exploded View Air Cleaner (ACL) Outlet Pipe-To-Throttle Body (TB) Adapter, Air Intake Resonator and PCV Tube Fuel Rail and Fuel Injectors Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 3562 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3567 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3568 Fuel Supply Line: Service and Repair Fuel Lines And Fuel Filter - Exploded View Fuel Lines and Fuel Filter - Exploded View 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3569 Fuel Supply Line: Service and Repair Fuel Lines Fuel Lines Removal 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: 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. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. 3. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. 4. Disconnect the Evaporative Emission (EVAP) canister vapor tube-to-EVAP purge valve quick connect coupling. 5. NOTE: LH side shown, RH side similar. If equipped, remove the 6 bolts and the transfer case skid plate. 6. If equipped, remove the front driveshaft. 106L (28 gal) fuel tank 7. Disconnect the front fuel supply tube-to-fuel tank fuel supply tube quick connect coupling. 127L (33.5 gal) fuel tank 8. Disconnect the front fuel supply tube-to-fuel filter outlet tube quick connect coupling. All vehicles 9. Disconnect the EVAP canister vapor tube-to-EVAP canister quick connect coupling and fresh air tube-to-EVAP canister quick connect coupling. 10. If equipped, remove the selector lever heat shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3570 11. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud. 12. Remove the 2 selector lever bracket bolts and remove the bracket. 13. Remove the front fuel supply tube, fuel vapor tube and fresh air tube pushpin from the bracket at the transmission bellhousing. 14. Disconnect the LH Heated Oxygen Sensor (HO2S) sensor electrical connector and remove the HO2S electrical connector wiring pushpin from the fuel supply tube, fuel vapor tube and fresh air tube bracket at the rear of the transmission housing. 15. NOTE: Front pushpin retainer shown, other similar. Disconnect the 3 transmission wiring harness pushpin retainers from the bracket at the transmission bellhousing, the transmission housing and the bracket at the rear of the transmission. 16. Remove the fuel supply tube, fuel vapor tube, and fresh air tube from the bracket at the rear of the transmission housing. 17. Remove the fuel supply tube, fuel vapor tube, and fresh air tube from the vehicle. Installation All vehicles 1. Install the fresh air tube into the vehicle and connect the pushpin retainer to the bracket at the bellhousing and install the line into the bracket at the Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3571 rear of the transmission. 2. Install the front fuel supply tube into the vehicle and clip it into the bracket at the bellhousing and install it into the bracket at the rear of the transmission. 3. Install the fuel vapor tube into the vehicle and clip it into the bracket at the bellhousing and install it into the bracket at the rear of the transmission. 4. NOTE: Front pushpin retainer shown, other similar. Connect the 3 transmission wiring harness pushpin retainers to the bracket at the transmission bellhousing, the transmission housing and the bracket at the rear of the transmission. 5. Install the HO2S electrical connector wiring pushpin to the fuel supply tube, fuel vapor tube, and fresh air tube bracket at the rear of the transmission housing and connect the LH HO2S sensor electrical connector. 6. Install the selector lever bracket and 2 bolts. - Tighten to 48 Nm (35 lb-ft). 7. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked in the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed. With the manual lever in NEUTRAL, connect the selector lever cable onto the manual lever ball stud and move the locking tab downward into the locked position. - Listen for the audible click. - Pull back on the selector lever cable to make sure it is correctly installed. 8. If equipped, install the selector lever heat shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3572 9. Connect the EVAP canister vapor tube-to-EVAP canister quick connect coupling and fresh air tube-to-EVAP canister quick connect coupling. 106L (28 gal) fuel tank 10. Connect the front fuel supply tube-to-fuel tank fuel supply tube quick connect coupling. 127L (33.5 gal) fuel tank 11. Connect the front fuel supply tube-to-fuel filter outlet tube quick connect coupling. All vehicles 12. If equipped, install the front driveshaft. 13. NOTE: LH side shown, RH side similar. If equipped, install the transfer case skid plate and 6 bolts. - Tighten to 25 Nm (18 lb-ft). 14. Connect the fuel supply tube-to-fuel rail quick connect coupling. 15. Connect the EVAP canister fuel vapor tube-to-EVAP purge valve quick connect coupling. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3578 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3579 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Fuel Tank Filler Pipe 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: 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: 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. NOTE: The upper fuel tank filler pipe assembly is serviceable separately from the lower fuel tank filler pipe assembly. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the fuel filler door cup bezel. 4. Remove the 3 fuel tank filler pipe-to-body screws. - To install, tighten to 1 Nm (9 lb-in). 5. Disconnect the fuel tank filler pipe vent tube-to-fuel tank pressure sensor and vapor tube assembly quick connect coupling. 6. Loosen the hose clamp and disconnect the fuel tank filler pipe hose-to-fuel tank. - To install, tighten to 3 Nm (27 lb-in). 7. Remove the 2 fuel tank filler pipe support brackets-to-frame bolts. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the fuel tank filler pipe assembly. 9. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: Customer Interest Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 3588 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 3594 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Level Control Solenoid Valve: All Technical Service Bulletins Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. 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 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module Fuel Gauge Sender: Locations Fuel Pump Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 3607 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 3608 Fuel Gauge Sender: Locations Fuel Pump (FP) Control Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 3609 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3610 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3613 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3616 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3617 Fuel Gauge Sender: Service and Repair Fuel Pump Module Fuel Pump Module 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3618 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. All fuel tanks 1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Service and Repair/Removal and Replacement/Fuel Tank. 127L (33.5 gal) fuel tank 2. Remove the 4 nuts and the Fuel Pump (FP) module cover. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the return fuel tube-to-FP module quick connect coupling. All fuel tanks 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. 5. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring. 106L (28 gal) fuel tank 6. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary. Remove the FP and FP O-ring seal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3619 - If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange. - Discard the FP O-ring seal. 127L (33.5 gal) fuel tank 7. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: Note the location of the FP alignment tabs. Remove the FP module assembly. Remove and discard the O-ring seal. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Fuel Pump Module Fuel Tank Unit: Locations Fuel Pump Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Fuel Pump Module > Page 3624 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Fuel Pump Module > Page 3625 Fuel Tank Unit: Locations Fuel Pump (FP) Control Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Fuel Pump Module > Page 3626 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Fuel Tank Unit Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Fuel Tank Unit > Page 3629 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 3632 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3642 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3643 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3644 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3645 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3646 Inertia Fuel Shutoff Switch: Service and Repair Inertia Fuel Shutoff (IFS) Switch Removal and Installation 1. NOTE: The Inertia Fuel Shutoff (IFS) switch is located behind the LH quarter trim panel access cover. Remove the LH quarter trim panel access cover. 2. Remove the power liftgate motor electrical connector pushpins from the power liftgate motor bracket. 3. NOTE: Slide the IFS switch out below the power liftgate motor bracket. Remove the 2 bolts and the IFS switch. To install, tighten to 2 Nm (18 lb-in). 4. Disconnect the IFS switch electrical connector. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3651 Intake Air Duct: Service and Repair Air Cleaner Outlet Pipe Air Cleaner Outlet Pipe Removal Navigator 1. Remove the 2 bolts and the engine appearance cover. All vehicles 2. Loosen the 2 Air Cleaner (ACL) outlet pipe clamps. 3. Remove the ACL outlet pipe. Installation Navigator 1. NOTE: The ACL outlet pipe should be securely sealed, with the ends flush with the flanges on both the ACL and the Throttle Body (TB) to prevent unusual engine noise. Position the ACL outlet pipe with the alignment indicator positioned as shown and tighten the 2 clamps. - Tighten to 4 Nm (35 lb-in). Expedition 2. NOTE: The ACL outlet pipe should be securely sealed, with the ends flush with the flanges on both the ACL and the TB to prevent unusual engine noise. Position the ACL outlet pipe and tighten the 2 clamps. Tighten to 4 Nm (35 lb-in). Navigator 3. Position the engine appearance cover and install the 2 bolts. - Tighten to 5 Nm (44 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3655 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3656 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Service and Repair Fuel Pump Control Unit: Service and Repair Fuel Pump Control Module Removal and Installation 1. Disconnect the fuel pump control module electrical connector. 2. Remove the 2 bolts and the fuel pump control module. - To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3664 Fuel Pump Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3665 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3669 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3670 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Accelerator Pedal Position Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3675 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3676 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3677 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3681 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3682 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls Air Flow Meter/Sensor: Description and Operation Electronic Engine Controls Electronic Engine Controls Mass Air Flow (MAF) Sensor The MAF sensor: - sends the PCM a signal indicating mass airflow rate of air entering the engine. - incorporates the Intake Air Temperature (IAT) sensor. For removal and installation, refer to Mass Air Flow (MAF) Sensor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls > Page 3685 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Electronic Engine Controls > Page 3686 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation > Page 3687 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 bolts and the MAF sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Description and Operation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Inertia Fuel Shutoff Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3697 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3698 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3699 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3700 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3701 Inertia Fuel Shutoff Switch: Service and Repair Inertia Fuel Shutoff (IFS) Switch Removal and Installation 1. NOTE: The Inertia Fuel Shutoff (IFS) switch is located behind the LH quarter trim panel access cover. Remove the LH quarter trim panel access cover. 2. Remove the power liftgate motor electrical connector pushpins from the power liftgate motor bracket. 3. NOTE: Slide the IFS switch out below the power liftgate motor bracket. Remove the 2 bolts and the IFS switch. To install, tighten to 2 Nm (18 lb-in). 4. Disconnect the IFS switch electrical connector. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3705 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3708 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3709 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal 1. Remove the Throttle Body (TB). 2. 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 ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 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 1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB. 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). 2. Install the TB. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Air Cleaner (ACL) Outlet Pipe-To-Throttle Body (TB) Adapter and Air Intake Resonator Throttle Body (TB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Page 3713 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. Disconnect the battery ground cable. 2. Remove the Air Cleaner (ACL) outlet pipe. 3. Disconnect the crankcase ventilation tube quick connect coupling from the ACL outlet pipe-to-Throttle Body (TB) adapter. 4. Release the clamp and remove the bolt and the air intake resonator assembly. 5. Remove the 3 ACL outlet pipe-to-TB adapter bolts. 6. Remove the ACL outlet pipe-to-TB adapter. 7. Disconnect the Electronic Throttle Control (ETC) electrical connector. 8. Disconnect the Throttle Position (TP) sensor electrical connector. 9. Remove the 4 bolts, the vibration damper and the TB assembly. - Discard the TB O-ring seal. Installation 1. Using a new O-ring seal, position the TB, the vibration damper and tighten the 4 bolts in 2 stages. - Stage 1: Tighten to 9 Nm (80 lb-in). - Stage 2: Tighten an additional 90 degrees (one-fourth turn). 2. Connect the TP sensor electrical connector. 3. Connect the ETC electrical connector. 4. Position the ACL outlet pipe-to-TB adapter. 5. Install the 3 ACL outlet pipe-to-TB adapter bolts. - Tighten to 10 Nm (89 lb-in). 6. Position the air intake resonator assembly, install the bolt and the clamp. - Tighten to 10 Nm (89 lb-in). 7. Connect the crankcase ventilation tube quick connect coupling to the ACL outlet pipe-to-TB adapter. 8. Install the ACL outlet pipe. 9. Connect the battery ground cable. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3717 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3720 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3721 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal 1. Remove the Throttle Body (TB). 2. 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 ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 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 1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the ETB. 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). 2. Install the TB. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Firing Order Firing Order: Specifications Firing Order Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Firing Order > Page 3731 Firing Order: Specifications Engine Cylinder Identification Engine Cylinder Identification Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Base ignition timing.............................................................................................................................. ........................10° Before Top Dead Center (BTDC) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 2 > Page 3739 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3742 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3743 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3744 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation LH Camshaft Position (CMP) sensor 1. Remove the Air Cleaner (ACL) outlet pipe. All CMP sensors 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3748 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3749 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3750 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt from the A/C compressor pulley. 3. Disconnect the A/C compressor electrical connector. 4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3751 7. To install, reverse the removal procedure. 8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3756 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3757 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3758 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3759 Ignition Coil: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3760 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3761 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3762 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3763 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3764 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil on Plug (COP) > Page 3767 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Engine Ignition Components - Exploded View Ignition Coil: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View Engine Ignition - RH Engine Ignition - LH 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 3770 Ignition Coil: Service and Repair Ignition Coil-On-Plug Ignition Coil-On-Plug Removal and Installation 1. Disconnect the ignition coil-on-plug electrical connector. 2. Remove the bolt and the ignition coil-on-plug. - Remove the ignition coil-on-plug, using a twisting motion while pulling up on the ignition coil-on-plug. - To install, tighten to 6 Nm (53 lb-in). 3. NOTE: Verify that the ignition coil-on-plug spring is correctly located inside the ignition coil-on-plug boot and that there is no damage to the tip of the boot. To install, reverse the removal procedure. - Apply a light coat of dielectric compound to the inside of the ignition coil boots. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3775 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3778 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 3779 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 3780 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 2 > Page 3786 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3789 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3790 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3791 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Removal and Installation LH Camshaft Position (CMP) sensor 1. Remove the Air Cleaner (ACL) outlet pipe. All CMP sensors 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3795 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3796 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3797 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt from the A/C compressor pulley. 3. Disconnect the A/C compressor electrical connector. 4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3798 7. To install, reverse the removal procedure. 8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. If a new lock cylinder with keys is replaced, the new PATS keys must be programmed. 4. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 3804 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3809 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3812 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3813 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3814 Knock Sensor: Service and Repair Knock Sensor (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark plug gap..................................................................................................................................... .................................1.05 ± 0.05 mm (0.039-0.043 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 3819 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................12 Nm (106 lb-in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3820 Spark Plug: Application and ID Spark plug............................................................................................................................................ ...................................................................HJFS-24FP Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3821 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3822 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Engine Ignition - RH Engine Ignition - LH 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 3825 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal NOTICE: The spark plug procedure must be followed exactly or damage to the cylinder head and spark plug will result. 1. Remove the ignition coil-on-plug. For additional information, refer to Ignition Coil-On-Plug See: Ignition Coil/Service and Repair/Ignition Coil-On-Plug. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plug. 3. Inspect the spark plug. Installation 1. Adjust the spark plug gap as necessary. For the correct spark plug gap specification, refer to Specifications. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Install the spark plug. - To install, tighten to 12 Nm (106 lb-in). 3. Install the ignition coil. For additional information, refer to Ignition Coil-On-Plug See: Ignition Coil/Service and Repair/Ignition Coil-On-Plug. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations Shift Interlock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 3832 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 3833 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Brake Shift Interlock Actuator - Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Apply the park brake. 2. Remove the lower and upper steering column shrouds. 3. Turn the ignition switch to the accessory position and apply the brake or actuate the Brake Shift Interlock Actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. 8. NOTE: When installing the BSIA, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Brake Shift Interlock Actuator - Column Shift > Page 3836 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Selector Lever Indicator Bulb Removal and Installation 1. Remove the selector lever assembly. 2. Release the 4 tabs on the selector lever bezel and lift the selector lever bezel up to the selector lever knob. 3. Remove the bulb retainers from the bezel and replace the bulb(s) as necessary. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3855 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3856 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3862 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3863 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 3872 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 3873 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 Expedition 2wd Workshop Manual (V8-5.4L (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 (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The Tow/Haul switch is not replaceable. If a new Tow/Haul switch is required, install a new selector lever assembly. 1. For additional information, refer to Selector Lever - Column Shift See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever - Column Shift. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 (TC) Switch - Column Shift > Page 3876 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal and Installation NOTE: The Tow/Haul switch is not serviced. If a new switch is required, install a new selector lever knob assembly. 1. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 3885 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 3886 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3891 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3892 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls Delayed/Harsh Downshifts TSB 10-12-4 07/05/10 5.4L 3V AND 6R80 TRANSMISSION - DELAYED/HARSH DOWNSHIFT ABOVE 40 MPH (64 KM/H) FORD: 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles built on or before 5/1/2010 and 2009-2010 F-150 vehicles built on or before 2/1/2010 and equipped with 5.4L 3V engine and 6R80 transmission may exhibit a delayed then harsh downshift during a commanded downshift at speeds above 40 MPH (64 Km/h). ACTION Follow the Service Procedure to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and ID vehicle. 2. Reprogram the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 67.03 and higher. This new calibration is not included in the VCM 2010.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the 1CM Calibration is: (1) AL3P-7J104-AC for all vehicles except the F-150 4X4. (2) AL3P-7J104-BC for F-150 4X4. b. Select the following from the IDS tool: (1) Toolbox (2) Powertrain (3) OBD Test Modes (4) Mode Level 9 Vehicle Info (5) 1CM Cal Part Number 3. Clear TCM keep alive memory (KAM) and adaptive tables. NOTE IT IS CRITICAL THAT 1CM KAM BE CLEARED FOR THIS PROCEDURE TO BE FULLY EFFECTIVE a. Using IDS: (1) Open Toolbox (2) Choose Powertrain Then Choose TCM (3) Choose Reset KAM Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 3898 b. Using PDS: (1) Choose all Tests and Calibrations (2) Scroll down the menu and choose reset 1CM 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 a stopped position with light throttle to 15 MPH (24 Km/h) and 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 1700-2000 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 seconds. g. Repeat steps (d-f) three (3) times. NOTE 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 101204A 2009-2010 Expedition, 1.0 Hr. Navigator, F-150: Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 10-12-4 > Jul > 10 > Engine, A/T Controls - Delayed/Harsh Downshifts > Page 3899 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3904 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3905 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3910 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3911 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3912 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3913 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3914 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 3920 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3921 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3922 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3923 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 Expedition 2wd Workshop Manual (V8-5.4L (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 3924 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3931 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3932 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Brake Shift Interlock Actuator - Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Apply the park brake. 2. Remove the lower and upper steering column shrouds. 3. Turn the ignition switch to the accessory position and apply the brake or actuate the Brake Shift Interlock Actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. 8. NOTE: When installing the BSIA, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Brake Shift Interlock Actuator - Column Shift > Page 3935 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3941 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3942 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Apply the park brake. 2. Remove the lower and upper steering column shrouds. 3. Turn the ignition switch to the accessory position and apply the brake or actuate the Brake Shift Interlock Actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. 8. NOTE: When installing the BSIA, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Column Shift > Page 3945 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3957 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3958 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3964 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 3965 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 (6R80) .............................................................................................................................................. 11.0 quarts (10.5 liters) NOTE: Indicates only approximate dry fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3970 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION FLUID Motorcraft MERCON LV ATF Ford P/N .............................................................................................................................................. ............................................................... XT-10-QLV Ford Specification ............................................. .............................................................................................................................................. MERCON LV Automatic transmissions that require MERCON LV should only use MERCON LV fluid. Refer to scheduled maintenance information to determine the correct service interval. Use of any fluid other than the recommended fluid may cause transmission damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill Fluid - A/T: Service and Repair Transmission Fluid Drain And Refill 6R80 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 3973 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 3974 - 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 3975 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 3976 Fluid - A/T: Service and Repair Transmission Fluid Exchange 6R80 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 3977 Fluid - A/T: Service and Repair Transmission Fluid Level Check 6R80 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain And Refill > Page 3978 to check the transmission fluid level. 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/Transmission Fluid Drain And Refill. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 3982 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 3983 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/Transmission Fluid Drain And Refill. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to................... .............................................................................................................................................................. ...................12 Nm (106 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 3987 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 3988 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 3989 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/Transmission Fluid Drain And Refill. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 Fluid Pump: Customer Interest A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. 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 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 > Page 3998 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 Fluid Pump: All Technical Service Bulletins A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. 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 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 > Page 4004 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 4010 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 4016 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Selector Lever Indicator Bulb Removal and Installation 1. Remove the selector lever assembly. 2. Release the 4 tabs on the selector lever bezel and lift the selector lever bezel up to the selector lever knob. 3. Remove the bulb retainers from the bezel and replace the bulb(s) as necessary. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4033 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4034 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4040 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4041 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 Seals and Gaskets: Customer Interest A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. 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 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 > Page 4050 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > By Symptom for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 Seals and Gaskets: By Symptom A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. 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 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > By Symptom for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 > Page 4056 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 Seals and Gaskets: All Technical Service Bulletins A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. 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 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 > Page 4062 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal Seals and Gaskets: Service and Repair Output Shaft Seal 6R80 Output Shaft Seal NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4065 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4066 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4067 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/Transmission Fluid Level Check. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4068 Seals and Gaskets: Service and Repair Manual Control Lever Shaft And Seal 6R80 Manual Control Lever Shaft and Seal Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the heat shield. 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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4069 6. Remove and discard the transmission fluid filter. 7. Remove the transmission fluid pan gasket. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4070 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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4071 15. Remove and discard the manual control lever seal. Installation 1. Position a new manual control lever seal in place. 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). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4072 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4073 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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4074 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. 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. Install the selector lever cable end onto the manual control lever ball stud. 18. Lock the selector lever cable lock tab. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Output Shaft Seal > Page 4075 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4083 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4084 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4089 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4090 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Apply the park brake. 2. Remove the lower and upper steering column shrouds. 3. Turn the ignition switch to the accessory position and apply the brake or actuate the Brake Shift Interlock Actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. 8. NOTE: When installing the BSIA, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Column Shift > Page 4093 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism Shifter A/T: Service and Repair Selector Lever Mechanism Selector Lever Mechanism Selector Lever Mechanism Removal 1. Remove the instrument panel lower finish panel. 2. Remove the steering column lower shroud. 1. Remove the screws and the lower shroud. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4099 3. Remove the steering column upper shroud. 4. Remove the Instrument Cluster (IC) shroud trim. 5. Remove the RH IC trim screw. 6. Remove the LH IC trim screw and pull the IC trim from the instrument panel. 7. If equipped, disconnect the in-vehicle temperature sensor connector. 8. Disconnect the dimmer switch electrical connector and remove the IC trim. 9. Remove the upper IC screws. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4100 10. Remove the RH lower IC screw. 11. Remove the LH lower IC screw and position the IC aside. 12. NOTICE: To prevent cable damage, do not apply force to the selector lever cable assembly between the steering column selector lever arm and the steering column bracket. Disconnect the selector lever cable. 13. Remove the locking pin and the park lock cable. 1. Remove and discard the locking pin. 2. Disconnect the park lock cable. 14. Disconnect the Tow/Haul switch electrical connector and the harness from the retaining clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4101 15. Remove the selector lever bolt. 16. Remove the selector lever. 17. Remove the selector lever mechanism lower bolt. 18. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector and remove the selector lever mechanism upper bolts and the selector lever mechanism from the vehicle. 19. Remove the BSIA from the selector lever mechanism. 1. Pull the BSIA override button. 2. Remove the BSIA screw. 3. Gently pry the clip up and remove the BSIA. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4102 Installation 1. Install the BSIA onto the selector lever mechanism. 1. Pull the BSIA override button. 2. Align the selector lever tab into the BSIA. 3. Position and secure the BSIA with the clip. 4. Install the screw. 2. Install the selector lever mechanism into the vehicle, install the upper bolts and connect the BSIA electrical connector. - Tighten to 6 Nm (53 lb-in). 3. Install the selector lever mechanism lower bolt. - Tighten to 6 Nm (53 lb-in). 4. Install the selector lever. - Tighten to 18 Nm (159 lb-in). 5. Connect the Tow/Haul switch electrical connector and the harness into the retaining clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4103 6. Install the locking pin and the park lock cable. 1. Connect the park lock cable. 2. Install a new locking pin. 7. NOTICE: To prevent cable damage, do not apply force to the selector lever cable assembly between the steering column selector lever arm and the steering column bracket. Connect the selector lever cable. 8. Position the IC and install the LH lower IC screw. 9. Install the RH lower IC screw. 10. Install the upper IC screws. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4104 11. Position the IC trim and connect the dimmer switch electrical connector. 12. If equipped, connect the in-vehicle temperature sensor connector. 13. Install the LH IC trim screw. 14. Install the RH IC trim screw. 15. Install the IC shroud trim. 16. Install the steering column upper shroud. 17. Install the steering column lower shroud. 1. Install the lower shroud and the screws. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4105 18. Install the instrument panel lower finish panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4106 Shifter A/T: Service and Repair Selector Lever Knob Selector Lever Knob Expedition Navigator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4107 Removal 1. NOTE: Expedition selector lever shown, Navigator similar. Remove the PRNDL trim, console tray and cup holder insert. 2. Remove the screw and the console upper trim. 3. Remove and discard the RH selector lever knob cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4108 1. Start at the bottom front only. 2. Move towards the top front and remove the cover. 4. Remove and discard the LH selector lever knob cover. 1. Start at the bottom front only. 2. Move towards the top front and remove the cover. 5. Remove and discard the RH selector lever knob screw. 6. NOTE: Verify the LH and RH knob body towers are present and not damaged. Remove and discard the LH selector lever knob screw. 7. Disconnect the Tow/Haul switch electrical connector and remove the selector lever knob. Installation 1. Connect the Tow/Haul switch electrical connector and install the selector lever knob. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4109 2. Install a new LH selector lever knob screw. - Tighten to 2 Nm (18 lb-in). 3. Install a new RH selector lever knob screw. - Tighten to 2 Nm (18 lb-in). 4. NOTE: Wood-trimmed vehicles have a rubber damper not found on other trim levels. Install a new LH selector lever knob cover. 5. NOTE: Wood-trimmed vehicles have a rubber damper not found on other trim levels. Install a new RH selector lever knob cover. 6. Install the console upper trim and the screw. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4110 7. Install the PRNDL trim, console tray and cup holder insert. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4111 Shifter A/T: Service and Repair Selector Lever Bezel Selector Lever Bezel Expedition Navigator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4112 Removal Funkmaster Flex vehicles 1. NOTE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Using an appropriate tool, slightly lift the lower RH corner of the serial numbered name plate upward to gain access to the double-sided adhesive tape, located on the bottom of the name plate. 2. NOTE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Starting at the RH corner of the serial numbered name plate, position a piano wire, or an equivalent tool, between the name plate and the floor console finish panel and cut the double-sided adhesive tape on the bottom of name plate. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4113 3. NOTE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Starting at the RH corner of the serial numbered name plate, position a piano wire, or an equivalent tool, between the name plate and the floor console finish panel and cut the double-sided adhesive tape on the bottom of name plate. 4. Remove the serial numbered name plate. All vehicles 5. NOTE: Expedition selector lever shown, Navigator similar. Remove the PRNDL trim, console tray and cup holder insert. 6. Remove the screw and the console upper trim. 7. Remove and discard the RH selector lever knob cover. 1. Start at the bottom front only. 2. Move towards the top front and remove the cover. 8. Remove and discard the LH selector lever knob cover. 1. Start at the bottom front only. 2. Move towards the top front and remove the cover. 9. Remove and discard the RH selector lever knob screw. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4114 10. NOTE: Verify the LH and RH knob body towers are present and not damaged. Remove and discard the LH selector lever knob screw. 11. Disconnect the Tow/Haul switch electrical connector and remove the selector lever knob. 12. Lift the tabs on the selector lever bezel and lift the bezel for access to the electrical harness. Expedition 13. Disconnect the electrical harness from the bezel. Installation Expedition 1. Connect the electrical harness onto the bezel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4115 All vehicles 2. Align the brake shift interlock override tab into its guide. 3. Install the selector lever bezel onto the selector lever housing. 4. Connect the Tow/Haul switch electrical connector and install the selector lever knob. 5. Install a new LH selector lever knob screw. - Tighten to 2 Nm (18 lb-in). 6. Install a new RH selector lever knob screw. - Tighten to 2 Nm (18 lb-in). 7. NOTE: Wood-trimmed vehicles have a rubber damper not found on other trim levels. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4116 Install a new LH selector lever knob cover. 8. NOTE: Wood-trimmed vehicles have a rubber damper not found on other trim levels. Install a new RH selector lever knob cover. 9. Install the console upper trim and the screw. 10. Install the PRNDL trim, console tray and cup holder insert. Funkmaster Flex vehicles 11. Using alcohol, remove the double-sided adhesive tape from the serial numbered name plate and floor console finish panel surfaces. 12. Use a suitable double-sided adhesive tape and apply 6 new tape strips to the bottom of the serial numbered name plate, as indicated. 13. Position the serial numbered name plate onto the floor console finish panel and apply downward pressure, to securely fasten the name plate to the floor console finish panel. 14. Verify brake shift interlock function. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4117 Shifter A/T: Service and Repair Selector Lever - Column Shift Selector Lever - Column Shift Removal and Installation 1. Remove the lower steering column shroud. 1. Remove the screws and the lower steering column shroud. 2. Remove the upper steering column shroud. 3. Disconnect the electrical connector and the harness from the retaining clips. 4. Remove the selector lever bolt. - To install, tighten to 18 Nm (159 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4118 5. Remove the selector lever. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4119 Shifter A/T: Service and Repair Selector Lever - Floor Shift Selector Lever - Floor Shift Expedition Navigator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4120 Removal Funkmaster Flex vehicles 1. NOTE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Using an appropriate tool, slightly lift the lower RH corner of the serial numbered name plate upward to gain access to the double-sided adhesive tape, located on the bottom of the name plate. 2. NOTE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Starting at the RH corner of the serial numbered name plate, position a piano wire, or an equivalent tool, between the name plate and the floor console finish panel and cut the double-sided adhesive tape on the bottom of name plate. 3. NOTE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4121 or damage the serial numbered name plate. Starting at the RH corner of the serial numbered name plate, position a piano wire, or an equivalent tool, between the name plate and the floor console finish panel and cut the double-sided adhesive tape on the bottom of name plate. 4. Remove the serial numbered name plate. Expedition 5. Remove the PRNDL trim, console tray and cup holder insert. 6. Remove the screw and the console upper trim. 7. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Disconnect the selector lever cable from the selector lever. 1. Disconnect the selector lever cable from the selector lever arm ball stud. 2. Disconnect the selector lever cable from the selector lever housing. 8. Disconnect the selector lever electrical connector. 9. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Remove the bolts and lift the selector lever out of the console. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4122 Navigator 10. Remove the selector lever trim plate. 11. NOTE: Using a suitable tool, lift and remove the floor console upper panel from the rear. Remove the floor console upper panel. 12. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Disconnect the selector lever cable from the selector lever arm ball stud. 13. Remove the center console LH kick panel. 14. Disconnect the selector lever cable from the selector lever housing. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4123 15. Disconnect the selector lever electrical connector. 16. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Remove the bolts and lift the selector lever out of the console. Installation Expedition 1. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Install the selector lever into the console. - Tighten to 8 Nm (71 lb-in). 2. Connect the selector lever electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4124 Connect the selector lever cable onto the selector lever. 1. Connect the selector lever cable onto the selector lever housing. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 2. Connect the selector lever cable onto the selector lever arm ball stud. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 4. Install the console upper trim and the screw. 5. Install the PRNDL trim, console tray and cup holder insert. Navigator 6. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Install the selector lever into the console. - Tighten to 8 Nm (71 lb-in). 7. Connect the selector lever electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4125 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Connect the selector lever cable onto the selector lever housing. 9. Install the center console LH kick panel. 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Connect the selector lever cable onto the selector lever arm ball stud. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 11. Install the floor console upper panel. 12. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the selector lever ball Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Mechanism > Page 4126 stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the selector lever ball stud. Install the selector lever trim plate. Funkmaster Flex vehicles 13. Using alcohol, remove the double-sided adhesive tape from the serial numbered name plate and floor console finish panel surfaces. 14. Use a suitable double-sided adhesive tape and apply 6 new tape strips to the bottom of the serial numbered name plate, as indicated. 15. Position the serial numbered name plate onto the floor console finish panel and apply downward pressure, to securely fasten the name plate to the floor console finish panel. All vehicles 16. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment See: Adjustments. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift Shift Cable: Service and Repair Selector Lever Cable And Bracket - Column Shift Selector Lever Cable and Bracket - Column Shift Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the instrument panel lower finish panel. 3. Remove the hood release cable lever. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4132 4. Remove the instrument panel lower reinforcement panel. 5. Remove the steering column lower shroud. 1. Remove the screws and the lower shroud. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable assembly between the steering column selector lever arm and the steering column bracket. Disconnect the selector lever cable from the steering column. 1. Disconnect the selector lever cable from the selector lever arm ball stud. 2. Carefully lift the locking tab and disconnect the selector lever cable from the steering column bracket. 3. Disconnect the selector lever cable retainer. 7. Push the rubber grommet and selector lever cable down through the dash panel. 8. If equipped, remove the heat shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4133 9. 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 selector lever cable from the manual control lever ball stud. 10. Remove the selector lever cable clip to release the selector lever cable from the selector lever cable bracket. 11. Remove the bolts and the selector lever cable bracket from the transmission. Installation 1. Install the selector lever cable bracket and bolts onto the transmission. - Tighten to 25 Nm (18 lb-ft). 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, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that the selector lever is locked into the selector lever cable bracket. Install the selector lever cable into the selector lever cable bracket. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4134 3. 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. NOTE: Apply pressure to the selector lever cable end while connecting it to the manual control lever to make sure the selector lever has not moved out of the DRIVE position. Connect the selector lever cable to the manual control lever ball stud. - Listen for the audible click. - Pull back on the selector lever cable to make sure that the selector lever cable is correctly installed. 4. Lock the selector lever cable lock tab. 5. NOTE: Install a new heat shield if it is loose on the cable. If equipped, install the heat shield. 6. Push the selector lever cable and rubber grommet up through the dash panel. 7. NOTICE: To prevent cable damage, do not apply force to the selector lever cable assembly between the steering column selector lever arm and the steering column bracket. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4135 Connect the selector lever cable onto the steering column. 1. Connect the selector lever cable retainer. 2. Connect the selector lever cable onto the steering column bracket. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 3. Connect the selector lever cable onto the selector lever arm ball stud. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 8. Install the steering column lower shroud. 1. Install the screws and the lower shroud. 9. Install the instrument panel lower reinforcement panel. - Tighten to 9 Nm (80 lb-in). 10. Install the hood release cable lever. - Tighten to 9 Nm (80 lb-in). 11. Install the instrument panel lower finish panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4136 12. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment See: Adjustments. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4137 Shift Cable: Service and Repair Selector Lever Cable And Bracket - Floor Shift Selector Lever Cable and Bracket - Floor Shift Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Funkmaster Flex vehicles 2. NOTE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Using an appropriate tool, slightly lift the lower RH corner of the serial numbered name plate upward to gain access to the double-sided adhesive tape, located on the bottom of the name plate. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4138 3. NOTE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Starting at the RH corner of the serial numbered name plate, position a piano wire, or an equivalent tool, between the name plate and the floor console finish panel and cut the double-sided adhesive tape on the bottom of name plate. 4. Remove the serial numbered name plate. Expedition 5. Remove the PRNDL trim, console tray and cup holder insert. 6. Remove the screw and the console upper trim. 7. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Disconnect the selector lever cable from the selector lever. 1. Disconnect the selector lever cable from the selector lever arm ball stud. 2. Disconnect the selector lever cable from the selector lever housing. Navigator 8. Remove the selector lever trim plate. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4139 9. NOTE: Using a suitable tool, lift and remove the floor console upper panel from the rear. Remove the floor console upper panel. 10. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Disconnect the selector lever cable from the selector lever arm ball stud. 11. Remove the center console LH kick panel. 12. Disconnect the selector lever cable from the selector lever housing. All vehicles 13. Remove the selector lever cable and rubber grommet. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4140 14. If equipped, remove the heat shield. 15. 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 selector lever cable from the manual control lever ball stud. 16. Remove the selector lever cable clip to release the selector lever cable from the selector lever cable bracket. 17. Remove the bolts and the selector lever cable bracket from the transmission. Installation All vehicles 1. Install the selector lever cable bracket and bolts onto the transmission. - Tighten to 25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4141 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, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that the selector lever is locked into the selector lever cable bracket. Install the selector lever cable into the selector lever cable bracket. 3. 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. Connect the selector lever cable onto the manual control lever ball stud. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 4. Lock the selector lever cable lock tab. 5. NOTE: Install a new heat shield if it is loose on the cable. If equipped, install the heat shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4142 6. Install the selector lever cable and rubber grommet. Expedition 7. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Connect the selector lever cable onto the selector lever. 1. Connect the selector lever cable onto the selector lever housing. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 2. Connect the selector lever cable onto the selector lever arm ball stud. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 8. Install the console upper trim and the screw. 9. Install the PRNDL trim, console tray and cup holder insert. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4143 Navigator 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Connect the selector lever cable onto the selector lever housing. 11. Install the center console LH kick panel. 12. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the selector lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the selector lever ball stud. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel. Connect the selector lever cable onto the selector lever arm ball stud. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 13. Install the floor console upper panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable And Bracket - Column Shift > Page 4144 14. Install the selector lever trim plate. Funkmaster Flex vehicles 15. Using alcohol, remove the double-sided adhesive tape from the serial numbered name plate and floor console finish panel surfaces. 16. Use a suitable double-sided adhesive tape and apply 6 new tape strips to the bottom of the serial numbered name plate, as indicated. 17. Position the serial numbered name plate onto the floor console finish panel and apply downward pressure, to securely fasten the name plate to the floor console finish panel. All vehicles 18. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment See: Adjustments. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > Page 4148 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis Torque Converter: Testing and Inspection Torque Converter Diagnosis 6R80 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/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/Special Testing Procedures - Perform Diagnostic Routines. Refer to Diagnosis By Symptom See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnostic Routines See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom Use the Diagnosis by Symptom to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and repair as required before changing the torque converter. 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. - Spark plugs - check for cracks, high resistance or broken insulators Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 4151 - 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 4152 Torque Converter: Testing and Inspection Torque Converter Contamination Inspection 6R80 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Material Transmission Cooler: Specifications Material Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Material > Page 4157 Transmission Cooler: Specifications Torque Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Transmission Cooling - 6R80 HD With Towing Package Transmission Cooler: Description and Operation Transmission Cooling - 6R80 HD With Towing Package Transmission Cooling The transmission fluid cooling system consists of: - transmission fluid cooler inlet and outlet tubes. - an in-tank transmission fluid cooler inlet tube. - a non-repairable in-tank transmission fluid cooler. - an auxiliary transmission fluid cooler inlet tube (HD). - an auxiliary transmission fluid cooler (HD). - an auxiliary transmission fluid cooler return tube (HD). The transmission fluid flows from the transmission to the in-tank transmission fluid cooler, to the auxiliary transmission fluid cooler and returns to the transmission. For Transmission Fluid Cooler Flow Backflushing and Cleaning, refer to Transmission Control Systems. See: Transmission Control Systems/Testing and Inspection 6R80 HD with Towing Package Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Transmission Cooling - 6R80 HD With Towing Package > Page 4160 Transmission Cooler: Description and Operation Transmission Cooling - 6R80 Base Package Transmission Cooling The transmission fluid cooling system consists of: - transmission fluid cooler inlet and outlet tubes. - an in-tank transmission fluid cooler inlet tube. - a non-repairable in-tank transmission fluid cooler. - an auxiliary transmission fluid cooler inlet tube (HD). - an auxiliary transmission fluid cooler (HD). - an auxiliary transmission fluid cooler return tube (HD). The transmission fluid flows from the transmission to the in-tank transmission fluid cooler, to the auxiliary transmission fluid cooler and returns to the transmission. For Transmission Fluid Cooler Flow Backflushing and Cleaning, refer to Transmission Control Systems. See: Transmission Control Systems/Testing and Inspection 6R80 Base Package Ford Expedition 2wd Workshop Manual (V8-5.4L (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: When internal wear or damage occurs in the transmission, metal particles and clutch plate material can travel into the torque converter, the transmission fluid cooler tubes, the in-tank transmission fluid cooler and the auxiliary transmission fluid cooler, if equipped. These contaminants are a major cause of recurring transmission concerns. To prevent future concerns, remove these contaminants from the cooling system before placing the transmission back into use. Refer to Transmission Control Systems for Transmission Fluid Cooler Backflushing and Cleaning. See: Transmission Control Systems/Testing and Inspection 1. Visually inspect for obvious signs of mechanical damage, incorrect component installation and system leaks. Repair as necessary. - Install a new or remanufactured radiator when transmission fluid is found leaking from the in-tank transmission fluid cooler. Refer to Cooling System. - Install a new O-ring when transmission fluid is found leaking between the radiator transmission fluid cooler and the transmission fluid cooler fitting (not the cooler tube into the fitting). Refer to the Component Test. See: Component Tests and General Diagnostics/Transmission Fluid Cooler Leaks At Radiator - Install a new auxiliary transmission fluid cooler if there is leakage from the transmission fluid cooler. Refer to Auxiliary Transmission Fluid Cooler See: Service and Repair/Auxiliary Transmission Fluid Cooler. 2. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 4163 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 Expedition 2wd Workshop Manual (V8-5.4L (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 4164 Transmission Cooler: Component Tests and General Diagnostics Transmission Fluid Cooler Transmission Fluid Cooler NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler and transmission fluid cooler tubes must be cleaned and backflushed. Use a torque converter/oil cooler cleaner. NOTE: Cleaning and backflushing the transmission fluid cooling system, along with following all the normal cleaning and inspection procedures during disassembly and reassembly, will keep contaminants from entering the transmission, causing a repeat repair. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back into use. Transmission Fluid Cooler Backflushing And Cleaning 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. Transmission Fluid Cooler Leaks At Radiator Transmission Cooling Component Test Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4165 Transmission Fluid Cooler Leaks at Radiator Transmission fluid may leak between the radiator transmission fluid cooler and the transmission fluid cooler fitting (not the cooler tube into the fitting), which may result in a residue of transmission fluid on the radiator tank around the fluid cooler fitting. The in-tank transmission fluid cooler is not serviceable. If installation of a new transmission fluid cooler is required, refer to Cooling System. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler Transmission Cooler: Service and Repair Auxiliary Transmission Fluid Cooler Auxiliary Transmission Fluid Cooler Removal 1. Remove the upper radiator cover. 1. Remove the fasteners. 2. Remove and discard the auxiliary transmission fluid cooler inlet hose clamp. 3. Disconnect the auxiliary transmission fluid cooler inlet hose from the cooler. 4. With the vehicle in NEUTRAL, position it on a hoist. 5. Position the flexible air deflector aside, then remove and discard the auxiliary transmission fluid cooler outlet hose clamp. 6. Disconnect the auxiliary transmission fluid cooler outlet hose from the cooler. 7. Remove the auxiliary transmission fluid cooler. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4168 Installation 1. Install the auxiliary transmission fluid cooler. 2. Connect the auxiliary transmission fluid cooler outlet hose to the cooler. 3. Install a new auxiliary transmission fluid cooler outlet hose clamp, then position the flexible air deflector back into place. 4. Connect the auxiliary transmission fluid cooler inlet hose to the cooler. 5. Install a new auxiliary transmission fluid cooler inlet hose clamp. 6. Install the upper radiator cover. 1. Install the fasteners. 7. Fill the transmission with fluid and verify correct operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4169 Transmission Cooler: Service and Repair Transmission Fluid Cooler Hoses Transmission Fluid Cooler Hoses Removal 1. Remove the upper radiator cover. 1. Remove the fasteners. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4170 2. Remove and discard the auxiliary transmission fluid cooler inlet hose clamps. 3. Disconnect the auxiliary transmission fluid cooler inlet hose from the coolers. 4. With the vehicle in NEUTRAL, position it on a hoist. 5. Position the flexible air deflector aside, then remove and discard the transmission fluid cooler tube secondary latches. 6. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes. 7. Remove and discard the transmission fluid cooler hose clamps. 8. Disconnect the transmission fluid cooler hoses from the coolers. Installation 1. Connect the transmission fluid cooler hoses to the coolers. 2. Install new transmission fluid cooler hose clamps. 3. Connect the transmission fluid cooler hoses to the transmission fluid cooler tubes. 4. Install new transmission fluid cooler tube secondary latches, then position the flexible air deflector back into place. 5. Connect the auxiliary transmission fluid cooler inlet hose to the coolers. 6. Install new auxiliary transmission fluid cooler inlet hose clamps. 7. Install the upper radiator cover. 1. Install the fasteners. 8. Fill the transmission with fluid and verify correct operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4171 Transmission Cooler: Service and Repair Transmission Fluid Cooler Tubes Transmission Fluid Cooler Tubes Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the pushpin and position the air deflector aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4172 3. Remove the transmission cooler tube secondary latches. 4. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler hoses. 5. Remove the transmission fluid cooler tube bracket nut from the front of the engine. 6. Remove the transmission fluid cooler tube bracket bolt from the RH side of the transmission. 7. NOTE: The transmission fluid cooler tube O-rings may remain in the transmission case. Carefully remove them from the case if retained. Remove the transmission fluid cooler tube bracket bolt and disconnect the transmission fluid cooler tubes from the transmission. 8. Remove and discard the 4 sway bar bracket nuts and lower the front sway bar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4173 9. NOTICE: Only use hand tools when removing the engine mount nuts or damage to the engine mount may occur. For Four-Wheel Drive (4WD) vehicles, remove the RH engine mount nuts and lift the engine approximately 25 mm (1 in) to gain clearance for the transmission cooler tubes. 10. Remove the transmission fluid cooler tubes from the vehicle. Installation 1. Position the transmission fluid cooler tubes in the vehicle. 2. Position the transmission fluid cooler tube bracket to the side of the transmission and install the transmission fluid cooler tube bracket bolt. - Tighten to 48 Nm (35 lb-ft). 3. Position the transmission fluid cooler tube bracket to the front of the engine and install the nut. - Tighten to 40 Nm (30 lb-ft). 4. Connect the transmission fluid cooler tubes to the transmission fluid cooler hoses. 5. Install the transmission cooler tube secondary latches. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4174 6. Reposition the air deflector and install the pushpin. 7. Position the sway bar in place and install 4 new sway bar bracket nuts. - Tighten to 55 Nm (41 lb-ft). 8. NOTICE: Only use hand tools when installing the engine mount nuts or damage to the engine mount may occur. For 4WD vehicles, lower the engine and install the RH engine mount nuts. - Tighten to 175 Nm (129 lb-ft). 9. NOTE: Inspect the case to make sure that the old transmission fluid cooler tube O-rings are not stuck in the case. NOTE: Install new transmission fluid cooler tube O-rings on the ends of the cooler lines prior to installing. Install new O-rings on the transmission fluid cooler tubes. 10. Position the transmission fluid cooler tubes into the transmission, then install the transmission fluid cooler tube bracket bolt. - Tighten to 25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4175 11. Fill the transmission with fluid and verify correct operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 4182 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 4183 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 Valve Body: Customer Interest A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. 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 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 10-18-1 > Sep > 10 > A/T Delayed Engagement/DTC's P0741/P0731/P0735 > Page 4192 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 Valve Body: All Technical Service Bulletins A/T - Delayed Engagement/DTC's P0741/P0731/P0735 TSB 10-18-1 09/27/10 5.4L WITH 6R75/6R80 - DELAYED FORWARD/REVERSE ENGAGEMENT - DTCS P0741, P0731, AND/OR P0735 - AFTER COLD START FORD: 2007-2010 Expedition 2009-2010 F-150 LINCOLN: 2009-2010 Navigator ISSUE Some 2007-2010 Expedition, 2009-2010 Navigator and F-150 vehicles equipped with a 5.4L engine and a 6R75/6R80 transmission may exhibit delayed forward/reverse engagement. Diagnostic trouble codes (DTCs) P0741, P0731, and/or P0735 for torque converter and/or gear ratio concerns may be stored in the powertrain control module (PCM). This concern typically occurs after cold start and in colder climates. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the mechatronic assembly. Refer to Workshop Manual (WSM), Section 307-01. 2. Inspect the fluid pump adapter seal molded frame for evidence of cracks, which are most often found in the corner(s) of the molded frame. a. If evidence of cracks are present, proceed to Step 3. b. If evidence of cracks are not present, do not continue with this article. Refer to WSM Section 307-01 for further diagnostics. 3. Partially disassemble the mechatronic assembly to access only the main oil pressure regulator valve located in the lower half. Refer to WSM, Section 307-01. 4. Inspect the main oil pressure regulator valve for free movement in its bore. a. If the valve moves easily in the bore, proceed to Step 5. b. If the valve does not move or sticks, remove the valve and clean both the valve and bore, reinstall the valve. Proceed to Step 5. 5. Reassemble the mechatronic assembly. Refer to WSM, Section 307-01. 6. Install a new front pump adapter seal. 7. Reinstall the mechatronic assembly. Refer to WSM, Section 307-01. 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 101801A 2007-2010 Expedition, 2.7 Hrs. 2009-2010 F-150, Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 10-18-1 > Sep > 10 > A/T - Delayed Engagement/DTC's P0741/P0731/P0735 > Page 4198 Navigator: Follow Service Procedure To Repair Mechatronic Includes Time To Remove And Install The Mechatronic And Reprogram (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7F401 01 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4199 Valve Body: Locations Check Ball Location Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4200 Valve Body: Diagrams Mechatronic Assembly Mechatronic Upper Half Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4201 Mechatronic Lower Half Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4202 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4203 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4204 Check Ball Location Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4205 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4206 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4207 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4208 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4209 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4210 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4211 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/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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 4220 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 4226 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Conventional Differential ..................................................................................................................... ..................................................... 4.5 Pints ( 2.13 L ) Limited Slip Differential ................................... ...................................................................................................................................... 4.25 Pints ( 2.01 L ) NOTE: Add 4 oz. (118 ml) of Additive Friction Modifier XL-3 (or equivalent) for complete refill of Ford Limited Slip axles Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4232 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Ford Part Name .................................................................................................................................. Motorcraft SAE 75W-140 Synthetic Rear Axle Lube Ford Part Number ............................................. .......................................................................................................................................... XY-75W140-QL Ford Part Specification .............................................................................................. ................................................................................. WSL-M2C192-A NOTE: Your vehicles rear axle is filled with a synthetic rear axle lubricant and is considered lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is required or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair Differential Output Shaft Bearing: Service and Repair Stub Shaft Pilot Bearing and Seal NOTE: The stub shaft seals must be replaced whenever the halfshafts are removed. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Page 4237 1. Remove the halfshaft assembly. 2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the Bearing Remover on the stub shaft pilot bearing oil seal only. Using the Slide Hammer and Bearing Remover, remove and discard the stub shaft pilot bearing and the stub shaft pilot bearing oil seal. 3. Inspect the seal journal for rust, nicks and scratches. Polish the seal journal surface with fine crocus cloth, if necessary. 4. Lubricate the new stub shaft pilot bearing with axle lubricant. 5. NOTE: Installation of the stub shaft pilot bearing or stub shaft oil seal without the correct tools can result in early bearing or seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new one. Place the stub shaft pilot bearing onto the Halfshaft Pilot Bearing Installer and Adapter. 6. Install the stub shaft pilot bearing into the rear axle housing bore. 7. 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 new seal onto a suitable installer. 8. NOTICE: Strike only the handle. Directly striking the installer tool will damage the seal. Carefully align the stub shaft pilot bearing seal with the housing bore and install the stub shaft pilot bearing seal flush in the differential housing. 9. NOTE: If a feeler gauge of the specification shown in the illustration can be inserted between the stub shaft oil seal and the differential housing, the stub shaft seal is not seated correctly. Remove the stub shaft oil seal and install a new stub shaft oil seal. Make sure the stub shaft oil seal is correctly seated in the differential housing. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Page 4238 10. NOTE: Inspect the stub shaft seal journal for rust, nicks or scratches prior to installing the halfshaft. Polish the seal journal with fine crocus cloth, if required. Install the halfshaft. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair Pinion Flange: Service and Repair Drive Pinion Flange and Drive Pinion Seal Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4242 Removal NOTICE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing preload during installation or damage to the component may occur. NOTE: Remove the rear wheel and tire assemblies, brake calipers and brake discs to prevent brake drag during the drive pinion bearing preload adjustment. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel and tire. 3. NOTICE: Do not allow the brake caliper to hang from the brake hose. Provide a suitable support or damage to the component may occur. Remove the rear brake discs. 4. Remove the rear driveshaft assembly. 5. Install a Nm (lb-in) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 6. NOTICE: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage to the component may occur. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove the pinion nut. - Discard the nut. 7. Index-mark the drive pinion flange and the drive pinion gear stem to maintain initial balance during installation. 8. Using the 2-Jaw Puller, remove the drive pinion flange. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4243 9. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. Installation 1. Lubricate the lips of the new drive pinion seal with grease. 2. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new seal. Using the Drive Pinion Oil Seal Installer, install the drive pinion seal. 3. Lubricate the drive pinion flange splines with rear axle lubricant. 4. NOTE: Disregard the index marks if installing a new drive pinion flange. Position the drive pinion flange. 5. Using the Drive Pinion Flange Installer, install the drive pinion flange. 6. 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 as the original. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4244 Select the correct drive pinion nut for installation. 7. Position the new drive pinion nut. 8. NOTICE: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new drive pinion collapsible spacer. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. NOTE: Remove the Drive Pinion Flange Holding Fixture while taking preload readings with the Nm (inch-pound) torque wrench. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the nut. - Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. - Refer to the torque specification for used pinion bearings in the Specifications portion. 9. NOTICE: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown or damage to the component may occur. NOTE: Align the index marks. Install the rear driveshaft. 10. Install the rear brake discs. 11. Install the rear wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Pilot Bearing And Seal Seals and Gaskets: Service and Repair Stub Shaft Pilot Bearing And Seal Stub Shaft Pilot Bearing and Seal NOTE: The stub shaft seals must be replaced whenever the halfshafts are removed. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Pilot Bearing And Seal > Page 4249 1. Remove the halfshaft assembly. 2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the Bearing Remover on the stub shaft pilot bearing oil seal only. Using the Slide Hammer and Bearing Remover, remove and discard the stub shaft pilot bearing and the stub shaft pilot bearing oil seal. 3. Inspect the seal journal for rust, nicks and scratches. Polish the seal journal surface with fine crocus cloth, if necessary. 4. Lubricate the new stub shaft pilot bearing with axle lubricant. 5. NOTE: Installation of the stub shaft pilot bearing or stub shaft oil seal without the correct tools can result in early bearing or seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new one. Place the stub shaft pilot bearing onto the Halfshaft Pilot Bearing Installer and Adapter. 6. Install the stub shaft pilot bearing into the rear axle housing bore. 7. 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 new seal onto a suitable installer. 8. NOTICE: Strike only the handle. Directly striking the installer tool will damage the seal. Carefully align the stub shaft pilot bearing seal with the housing bore and install the stub shaft pilot bearing seal flush in the differential housing. 9. NOTE: If a feeler gauge of the specification shown in the illustration can be inserted between the stub shaft oil seal and the differential housing, the stub shaft seal is not seated correctly. Remove the stub shaft oil seal and install a new stub shaft oil seal. Make sure the stub shaft oil seal is correctly seated in the differential housing. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Pilot Bearing And Seal > Page 4250 10. NOTE: Inspect the stub shaft seal journal for rust, nicks or scratches prior to installing the halfshaft. Polish the seal journal with fine crocus cloth, if required. Install the halfshaft. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Pilot Bearing And Seal > Page 4251 Seals and Gaskets: Service and Repair Drive Pinion Flange And Drive Pinion Seal Drive Pinion Flange and Drive Pinion Seal Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Pilot Bearing And Seal > Page 4252 Removal NOTICE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing preload during installation or damage to the component may occur. NOTE: Remove the rear wheel and tire assemblies, brake calipers and brake discs to prevent brake drag during the drive pinion bearing preload adjustment. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel and tire. 3. NOTICE: Do not allow the brake caliper to hang from the brake hose. Provide a suitable support or damage to the component may occur. Remove the rear brake discs. 4. Remove the rear driveshaft assembly. 5. Install a Nm (lb-in) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 6. NOTICE: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage to the component may occur. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove the pinion nut. - Discard the nut. 7. Index-mark the drive pinion flange and the drive pinion gear stem to maintain initial balance during installation. 8. Using the 2-Jaw Puller, remove the drive pinion flange. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Pilot Bearing And Seal > Page 4253 9. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. Installation 1. Lubricate the lips of the new drive pinion seal with grease. 2. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new seal. Using the Drive Pinion Oil Seal Installer, install the drive pinion seal. 3. Lubricate the drive pinion flange splines with rear axle lubricant. 4. NOTE: Disregard the index marks if installing a new drive pinion flange. Position the drive pinion flange. 5. Using the Drive Pinion Flange Installer, install the drive pinion flange. 6. 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 as the original. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Stub Shaft Pilot Bearing And Seal > Page 4254 Select the correct drive pinion nut for installation. 7. Position the new drive pinion nut. 8. NOTICE: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new drive pinion collapsible spacer. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. NOTE: Remove the Drive Pinion Flange Holding Fixture while taking preload readings with the Nm (inch-pound) torque wrench. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the nut. - Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. - Refer to the torque specification for used pinion bearings in the Specifications portion. 9. NOTICE: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown or damage to the component may occur. NOTE: Align the index marks. Install the rear driveshaft. 10. Install the rear brake discs. 11. Install the rear wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > General Specifications Axle Shaft Assembly: Specifications General Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > General Specifications > Page 4260 Axle Shaft Assembly: Specifications Material Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > General Specifications > Page 4261 Axle Shaft Assembly: Specifications Torque Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Page 4262 Axle Shaft Assembly: Description and Operation Rear Drive Halfshafts NOTE: The outboard CV joint shaft assembly should not be disassembled. NOTE: Due to the sub-assembly process, if the outboard CV boot needs replacement, the inboard CV boot must also be replaced. However, the inboard CV boot can be replaced by itself. 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 - CV 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 front wheels including jounce and rebound plus changes while turning. The CV joints are caged ball type. New halfshaft components are available as kits containing grease, boots and clamps. Halfshaft Handling 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Page 4263 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Halfshaft Removal and Installation NOTE: This procedure applies to both rear halfshaft assemblies. NOTE: Always install a new differential stub shaft seal whenever a rear halfshaft is removed. 1. NOTICE: Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly is removed from the vehicle. Wheel Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4266 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 wheel and tire. 3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the rear axle wheel hub retainer and the washer. - To install, tighten to 350 Nm (258 lb-ft). 4. Separate the halfshaft from the knuckle. 5. Remove the brake disc rotor. 6. Remove the upper trailing arm bolt. - To install, tighten to 250 Nm (184 lb-ft). 7. Remove the upper trailing arm-to-wheel knuckle nut. - To install, tighten to 103 Nm (76 lb-ft). 8. Using the Ball Joint Separator, separate the upper arm from the wheel knuckle. 9. Remove and discard the stabilizer bar link nut. - To install, tighten the new nut to 63 Nm (46 lb-ft). 10. Remove the toe link-to-wheel knuckle bolt. - To install, tighten 225 Nm (166 lb-ft). 11. Disconnect the anti-lock brake sensor at the connector and open the wire retaining clips. 12. Compress the spring, depress the retaining tabs and detach the parking brake cable from the wheel knuckle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4267 13. Remove the 2 lower trailing arm-to-wheel knuckle bolts. - To install, tighten to 103 Nm (76 lb-ft). 14. Rotate the top of the knuckle assembly outboard and remove the halfshaft from the knuckle. 15. Using the Halfshaft Remover and Adapter (Handle), disengage the inboard CV joint housing from the differential side gear. 16. Remove the halfshaft assembly from the vehicle. 17. Remove and discard the halfshaft retainer circlip. 18. NOTE: Install a new differential stub shaft seal. NOTE: Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub retainer. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4268 Axle Shaft Assembly: Overhaul Halfshaft Joint Disassembly 1. Remove the halfshaft from the vehicle. For additional information, refer to Halfshaft See: Removal and Replacement in the Removal and Installation portion. 2. NOTE: Do not damage the boot. Remove the 2 boot clamps. 3. Separate the boot from the inboard CV joint housing. 4. Remove the retaining ring. 5. Remove the inboard CV joint housing. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4269 6. Index-mark the inner race and ball cage. 7. Remove the 8 balls. 8. Remove the snap ring. 9. Remove the inner race and the ball cage. 10. Remove the inboard boot. 11. Remove the 2 boot clamps. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4270 12. Remove the outboard boot. 13. NOTE: If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV joint and interconnecting shaft assembly if worn/damaged. Check the grease for contamination. Assembly 1. Position the outboard boot on the shaft. 2. Pack the outboard CV joint with 175 g (6.17 oz) of grease. 1. Use CV joint grease or equivalent provided in the boot kit. 2. Spread any remaining grease from the kit evenly inside the boot. 3. Install the outboard boot. 1. Clean the boot mounting surface. 2. Seat the boot in the joint boot groove. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4271 4. Position the 2 boot clamps. 5. NOTE: Tighten the through-bolt until the tool is in the closed position. Using the Constant Velocity Joint Boot Clamp Installer, install the 2 boot clamps. 6. Position the boot clamp on the shaft. 7. Position the inboard boot on the shaft. 8. Position the ball cage on the shaft with the tapered end facing the boot. 9. NOTE: Align the index marks. Position the inner race on the shaft with the counterbored end facing the boot. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4272 10. Install the snap ring. 11. Lubricate and position the 8 balls. - Use CV joint grease or equivalent provided in the boot kit. 12. Fill the inboard CV joint housing with 225 g (7.94 oz) of grease. - Use CV joint grease or equivalent provided in the boot kit. 13. Position the boot clamp on the inboard CV joint housing. 14. Position the inboard CV joint housing on the ball and race assembly. 15. Install the retaining ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4273 16. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove. 17. Set the halfshaft assembled length to specification. For additional information, refer to Specifications. 18. NOTE: Do not damage the boot. Insert a dull screwdriver blade under the boot to release the pressure. 19. NOTE: Tighten the through-bolt until the tool is in the closed position. Using the Constant Velocity Joint Boot Clamp Installer, install the 2 boot clamps. 20. NOTICE: Verify the spline engagement by checking for spline lash before installing the halfshaft nut or damage to the component may occur. Install the halfshaft in the vehicle. For additional information, refer to Halfshaft See: Removal and Replacement in the Removal and Installation portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 parts, 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. Disconnect the wheel speed sensor electrical connector. 2. Remove the wheel and tire. 3. Remove the wheel speed sensor harness bracket bolt and detach the harness from the retainers. - To install, tighten to 12 Nm (106 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4278 4. NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose may result. Remove the 2 bolts and position the caliper and anchor plate aside. - Support the caliper using mechanic's wire. - To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the 4 bolts and the wheel bearing and wheel hub. - Discard the bolts. - To install, tighten to 175 Nm (129 lb-ft). 7. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel speed sensor. - To install, tighten to 18 Nm (159 lb-in). 8. NOTICE: If the original wheel bearing and wheel hub is being installed, a new O-ring seal must be installed or damage to the wheel bearing may occur. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4279 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing and Wheel Hub Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital parts 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 installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4280 1. Remove the wheel and tire. 2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the halfshaft nut. 3. Using a suitable hub puller, 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 may result. Remove the bolts and position the caliper and anchor plate assembly aside. - Support the caliper and anchor plate assembly using mechanic's wire. 5. Remove the brake disc. 6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 7. Remove the 4 bolts, the wheel bearing and wheel hub, and the wheel speed sensor as an assembly. - Route the sensor wiring through the access hole in the brake disc shield. - Discard the bolts. 8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and wheel hub. Installation 1. If necessary, install the wheel speed sensor and bolt. - Tighten to 18 Nm (159 lb-in). 2. Position the wheel bearing and wheel hub, and the wheel speed sensor. Install the 4 new wheel bearing and wheel hub bolts. - Route the sensor wiring through the access hole in the brake disc shield. - Tighten to 175 Nm (129 lb-ft). 3. Attach the wheel speed sensor harness to the retainers and connect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 4. Install the brake disc. 5. Position the caliper and anchor plate assembly and install the bolts. - Tighten to 190 Nm (140 lb-ft). 6. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Install the new halfshaft nut. - Tighten to 300 Nm (221 lb-ft). 7. Install the wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Rear Suspension Wheel Bearing and Wheel Hub Install the new halfshaft nut, tighten to .................................................................................................................................................... 300 Nm (221 lb-ft) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations Wheel Hub Lock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 4288 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 4289 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Service and Repair Wheel Hub (Locking): Service and Repair Integrated Wheel End (IWE) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire. 3. Remove the dust cap. 4. Remove and discard the axle nut. 5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE). 6. Remove the 3 IWE-to-wheel knuckle retaining bolts. 7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle. - Discard the tie-rod nut. 8. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 9. Remove the front brake flexible hose bracket bolt and position the brake hose aside. 10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle. - Discard the upper ball joint nut. 11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing. 12. Remove the IWE from the halfshaft outboard end. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Service and Repair > Page 4293 1. Compress the IWE and install a vacuum cap on the vacuum port. 2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE on halfshaft outboard end or component damage may occur. Install the IWE onto the halfshaft outboard end. 3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing. 4. Connect the upper ball joint and install a new nut. - Tighten to 115 Nm (85 lb-ft). 5. Connect the tie rod and install a new nut. - Tighten to 115 Nm (85 lb-ft). 6. Position the front brake flexible hose bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the wheel speed sensor harness bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 8. Install the 3 IWE-to-wheel knuckle retaining bolts. - Tighten to 12 Nm (106 lb-in). 9. Remove the IWE vacuum cap and connect the vacuum tubes. 10. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle nut or component damage may occur. Install the new axle nut. - Tighten to 27 Nm (20 lb-ft). 11. Install the dust cap. 12. Install the front wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and U-joints to prevent overspray of any undercoating material. Vehicles have the following types of driveshafts: - Front driveshaft with CV joints at the front and rear. The front driveshafts are not serviced - One-piece rear driveshafts with a front and a rear U-joint flange - Two-piece rear driveshafts with a front U-joint, center bearing with a slip joint and a flanged U-joint at the rear Driveshafts are used to transfer movement from the transmission or transfer case to the front or rear axle. The driveshaft is composed of the U-joints, CV joints, connecting shafts and the attaching yokes. Some vehicles are equipped with a center support bearing. The center support bearing is prelubricated and sealed for the life of the bearing. Driveshafts differ in length, diameter and type of yoke to accommodate various wheelbase and powertrain combinations. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 section 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4300 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4301 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4302 - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4303 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4304 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4305 Drive/Propeller Shaft: Removal and Replacement Driveshaft - Front Driveshaft - Front Removal and Installation 1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 2. Index-mark the front flange to the pinion flange. 3. Index-mark the rear flange to the transfer case flange. 4. Remove and discard the 6 rear flange-to-transfer case flange bolts and 3 washers. - To install, tighten to 55 Nm (41 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4306 5. Remove and discard the 6 front flange-to-pinion flange bolts and 2 washers. - To install, tighten to 55 Nm (41 lb-ft). 6. Remove and discard the 4 stabilizer bracket nuts and allow the stabilizer bar to swing downward. - To install, tighten to 55 Nm (41 lb-ft). 7. Remove the front driveshaft from the vehicle. 8. To install, reverse the removal procedure. Driveshaft - Rear Driveshaft - Rear Four-Wheel Drive (4WD) Vehicles Rear Wheel Drive (RWD) Vehicles Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4307 Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Index-mark the driveshaft flange to the pinion flange. 3. Index-mark the driveshaft slip yoke to the transfer case housing. 4. Remove and discard the 4 driveshaft flange bolts. 5. NOTICE: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange or damage to the component may occur. Using a suitable tool, disconnect the driveshaft flange from the pinion flange. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4308 6. NOTE: Align the original index-marks at the transfer case. Do not rotate the driveshaft when removing the slip yoke from the transfer case output shaft. Remove the driveshaft. - Mark the transfer case output shaft to the transfer case housing after removing the driveshaft. Rear Wheel Drive (RWD) vehicles 7. Index-mark the driveshaft flanges for correct alignment during installation. 8. Remove and discard the 4 driveshaft front flange bolts. 9. Remove and discard the 4 driveshaft rear flange bolts. 10. NOTICE: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange or damage to the component may occur. Using a suitable tool, disconnect the driveshaft flange from the pinion flange. 11. Remove the 2 driveshaft center bearing bolts, then remove the driveshaft. - Discard the driveshaft center bearing bolts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4309 Installation 4WD vehicles 1. Align all the index marks and install the driveshaft slip yoke into the transfer case housing. 2. NOTICE: The driveshaft flange fits tightly on the pinion flange pilot. To make sure that the driveshaft flange seat squarely on the pinion flange pilot, tighten the driveshaft flange bolts evenly in a cross pattern or damage to the component may occur. Align the index marks and install the driveshaft flange and the 4 driveshaft flange bolts. - Tighten to 103 Nm (76 lb-ft). RWD vehicles 3. NOTE: If new driveshaft center bearing bolts are not available, coat the threads of the original driveshaft center bearing bolts with threadlock sealer. Position the driveshaft center bearing and hand-tighten the 2 new driveshaft center bearing bolts until the driveshaft is mounted to the flanges. - Tighten to 48 Nm (35 lb-ft). 4. Install the 4 new driveshaft front flange bolts. - Tighten the bolts to 103 Nm (76 lb-ft). 5. NOTICE: The driveshaft flange fits tightly on the pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange pilot, tighten the driveshaft flange bolts evenly in a cross pattern or damage to the component may occur. Install the 4 new driveshaft rear flange bolts. - Tighten to 103 Nm (76 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4310 Driveshaft Slip Yoke Boot Driveshaft Slip Yoke Boot Removal and Installation 1. Remove the driveshaft. For additional information, refer to Driveshaft - Rear See: Driveshaft Rear. 2. Index-mark the driveshaft to the center bearing for correct alignment during installation. 3. Remove clamps and disconnect the slip yoke boot. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4311 4. Separate the driveshaft. 5. Remove the slip yoke boot. 6. NOTE: Lubricate the slip yoke splines with premium long-life grease. To install, reverse the removal procedure. - Align the index marks for correct alignment. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4312 Drive/Propeller Shaft: Overhaul Driveshaft - Exploded View Front, Expedition and Navigator Rear - Navigator Four-Wheel Drive (4WD), Expedition 4WD and Rear Wheel Drive (RWD) Rear, Navigator Rear Wheel Drive (RWD) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4313 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation Universal Joints U-joints are composed of the following: - Spiders - Trunnions - Grease seals - Needle rollers - Bearing cups - Thrust washers - Snap rings The U-joint is a method of connecting the driveshaft to the drive axle. A U-joint allows the angles of the output shafts, driveshafts and pinions to rotate smoothly while constantly accelerating and decelerating. The U-joint is lubricated for the life of the vehicle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 4317 Universal Joint: Service and Repair Driveshaft Universal Joint - Single Cardan Disassembly 1. Remove the driveshaft. For additional information, refer to Driveshaft - Front See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Driveshaft - Front or Driveshaft - Rear See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Driveshaft - Rear. 2. NOTICE: Do not clamp the driveshaft in the jaws of a vise or a similar holding fixture or damage to the component may occur. Carefully place the driveshaft on a suitable workbench. 3. NOTE: Index-mark the driveshaft components relative to the driveshaft tube. Make sure all components are reassembled in the same relationship to maintain correct balance. Index the driveshaft and driveshaft components. 4. Position the C-Frame and Screw Installer/Remover in a vise. 5. Remove the snap rings from the U-joint. 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft flange yoke. 1. Position the driveshaft flange in the C-Frame and Screw Installer/Remover. 2. Press out the bearing cup. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 4318 3. Rotate the driveshaft flange yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft flange yoke. 7. Repeat the previous step to remove the remaining bearing cups and spider from the driveshaft. 8. Clean the yoke area at the end of the driveshaft and flange yoke. Assembly NOTE: U-joint service kits are to be installed as complete assemblies only. Do not use components from other U-joints. 1. Clamp the C-Frame and Screw Installer/Remover in a vise. 2. Install a new bearing cup. 1. Start a new bearing cup into the driveshaft yoke. 2. Position a new spider in the driveshaft yoke. 3. Install the driveshaft into the C-Frame and Screw Installer/Remover. 4. Press the bearing cup below the yoke surface. 3. Remove the driveshaft from the C-Frame and Screw Installer/Remover and install the snap ring. 4. Repeat the previous steps to install the remaining bearing cups. 5. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 4319 Check the U-joint for freedom of movement. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Install the flexplate and the 8 bolts in the sequence shown. Tighten to............................................... ........................................................................................................................................................80 Nm (59 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Procedures > Page 4325 Flex Plate: Removal and Replacement Flexplate Removal and Installation 1. Remove the transmission. 2. Remove the 8 bolts and the flexplate. - To install, tighten to 80 Nm (59 lb-ft) in the sequence shown. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Selector Lever Indicator Bulb Removal and Installation 1. Remove the selector lever assembly. 2. Release the 4 tabs on the selector lever bezel and lift the selector lever bezel up to the selector lever knob. 3. Remove the bulb retainers from the bezel and replace the bulb(s) as necessary. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4347 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4348 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4354 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4355 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 4364 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 4365 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 Expedition 2wd Workshop Manual (V8-5.4L (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 (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The Tow/Haul switch is not replaceable. If a new Tow/Haul switch is required, install a new selector lever assembly. 1. For additional information, refer to Selector Lever - Column Shift See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever - Column Shift. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations Shift Interlock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 4374 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 4375 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Brake Shift Interlock Actuator - Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. Apply the park brake. 2. Remove the lower and upper steering column shrouds. 3. Turn the ignition switch to the accessory position and apply the brake or actuate the Brake Shift Interlock Actuator (BSIA) override. 4. Put the selector lever into the NEUTRAL position. 5. Disconnect the BSIA electrical connector. 6. Remove the BSIA screw. 7. Gently pry the clip up and remove the BSIA. 8. NOTE: When installing the BSIA, verify that the BSIA override has been activated and the slider is fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever tab into the BSIA. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Brake Shift Interlock Actuator - Column Shift > Page 4378 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Selector Lever Indicator Bulb Removal and Installation 1. Remove the selector lever assembly. 2. Release the 4 tabs on the selector lever bezel and lift the selector lever bezel up to the selector lever knob. 3. Remove the bulb retainers from the bezel and replace the bulb(s) as necessary. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: Customer Interest Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4397 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4398 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts Control Module: All Technical Service Bulletins Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts TSB 09-15-8 08/10/09 5.4L 3V 6R80 - HARSH 1-2 UPSHIFT - HARSH 2-1 DOWNSHIFT WHILE COASTING - HARSH DOWNSHIFT TO 4TH GEAR - INTERMITTENT P0741 FORD: 2009 Expedition LINCOLN: 2009 Navigator ISSUE Some 2009 Expedition and Navigator vehicles equipped with 5.4L 3V engine may exhibit symptoms during warm-up: a harsh 1-2 upshift, harsh 2-1 downshift while coasting 15 MPH (24 Km/h). A harsh downshift into 4th gear at highway speeds 45-70 MPH (72-113 Km/h) may also be experienced. Some vehicles may have a diagnostic trouble code (DTC) P0741 torque converter performance code present or stored. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID vehicle. 2. Update the Powertrain Control Module/Transmission Control Module (PCM/TCM) calibration using IDS release 61.15 and higher or 62.03 and higher. This new calibration is not included in the VCM 2009.5 DVD. Calibration files may also be obtained at the website. NOTE THE TCM CANNOT BE INDEPENDENTLY REPROGRAMMED, REPROGRAM USING THE PMI FUNCTION TO ENSURE THAT ENGINE AND TRANSMISSION CALIBRATIONS ARE UPDATED TO THE LATEST LEVEL SIMULTANEOUSLY. a. Verify that the TCM Calibration shows AL3P-7J104-AB part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode Level 9 Vehicle Info. (5) TCM Cal Part Number. NOTE IT IS CRITICAL THAT TCM KEEP ALIVE MEMORY (KAM) BE CLEARED FOR TSB TO BE FULLY AFFECTIVE 3. Clear TCM KAM and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4404 (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 DISCONNECTING 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 (79° C). If it is not at 175° F (79° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (79° 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 a stopped position with light throttle to 15 MPH (24Km/h) and 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 1700-2000 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 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 091508A 2009 Expedition, Navigator 1.0 Hr. 6R80 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear The TCM KAM And Perform Road Tests (Do Not Use With 12650D, 12651D, 12651D4) DEALER CODING Ford Expedition 2wd Workshop Manual (V8-5.4L (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: > 09-15-8 > Aug > 09 > Engine, A/T Controls - Harsh 1-2/2-1/5-4 Shifts > Page 4405 CONDITION BASIC PART NO. CODE RECAL 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 4414 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Locations > Page 4415 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 Expedition 2wd Workshop Manual (V8-5.4L (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 (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The Tow/Haul switch is not replaceable. If a new Tow/Haul switch is required, install a new selector lever assembly. 1. For additional information, refer to Selector Lever - Column Shift See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever - Column Shift. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations ABS Sensor Block: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 4423 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 4424 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Vehicles with floor shift 1. Remove the front floor console. 2. Remove the 4 bolts and the front floor console support bracket. - To install: Tighten the upper bolts to 9 Nm (80 lb-in). - Tighten the lower bolts to 40 Nm (30 lb-ft). Vehicles with column shift 3. Remove the stability control sensor cover. All vehicles 4. Disconnect the stability control sensor cluster electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 4428 5. Remove the 2 bolts and the stability control sensor cluster. - To install, tighten to 12 Nm (106 lb-in). 6. To install, reverse the removal procedure. - Connect the scan tool and carry out the IVD Initialization sequence. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4432 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4433 Electronic Brake Control Module: Diagrams Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4434 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4435 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4436 NOTE: On vehicles equipped with Roll Stability Control (RSC(R)), the ABS module and the Hydraulic Control Unit (HCU) are calibrated to one another. Do not swap ABS modules between RSC(R)-equipped vehicles. NOTE: On vehicles equipped with RSC(R), the ABS module is available separately from the HCU and should be serviced separately. However, if the RSC(R)-equipped vehicle requires a new HCU, then the ABS module and the HCU must be installed as an assembly. Make sure to use the most recently released service parts. NOTE: When installing a new ABS module/HCU assembly, it must be configured (either by download/upload or uploading the as-built data method). 1. Release the Air Cleaner (ACL) cover retaining clips and disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the ACL outlet clamp and disconnect the ACL cover from the outlet pipe. - To install, tighten to 4 Nm (35 lb-in). 3. Remove the 3 HCU bracket-to-frame bolts. - To install, tighten to 20 Nm (177 lb-in). 4. Disconnect the ABS module electrical connector. 5. Remove the 4 ABS module bolts and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 6. To install, reverse the removal procedure. 7. If installing a new ABS module on a vehicle equipped with RSC(R), configure the ABS module. 8. If installing a new ABS module on a vehicle equipped with RSC(R), calibrate the RSC(R) sensor. Connect the scan tool and carry out the IVD Initialization sequence. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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. NOTE: On vehicles equipped with Roll Stability Control (RSC(R)), the ABS module and the Hydraulic Control Unit (HCU) are calibrated to one another. Do not swap ABS modules between RSC(R)-equipped vehicles. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 4440 NOTE: On vehicles equipped with RSC(R), the ABS module is available separately from the HCU and should be serviced separately. However, if the RSC(R)-equipped vehicle requires a new HCU, then the ABS module and the HCU must be installed as an assembly. Make sure to use the most recently released service parts. NOTE: When installing a new ABS module/HCU assembly, it must be configured (either by download/upload or uploading the as-built data method). 1. Disconnect the ABS module electrical connector. 2. NOTICE: Only authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and only authorized parts should be used when installing new inlet brake tubes. Use of other than authorized inlet brake tubes may result in damage to the components. NOTE: Plug each open port to prevent brake fluid from spilling. Disconnect the 6 brake tube fittings. - To install: Tighten the master cylinder brake tube fittings to 25 Nm (18 lb-ft). - Tighten the remaining brake tube fittings to 20 Nm (177 lb-in). 3. Remove the 3 HCU-to-bracket bolts and the HCU. - To install, tighten to 9 Nm (80 lb-in). 4. To install, reverse the removal procedure. - Bleed the brake system. 5. If installing a new ABS module/HCU assembly on a vehicle equipped with RSC(R), configure the ABS module. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. Disconnect the steering wheel rotation sensor electrical connector. 2. Remove the 2 bolts and the steering wheel rotation sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. 4. NOTE: If the sensor is not calibrated after installation, a DTC will be set in the ABS module. Calibrate the sensor in the following sequence: 1. Start the engine. 2. Rotate the steering wheel from lock to lock a minimum of 2 times. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 4447 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 4448 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 4453 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4454 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4455 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4456 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4457 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4458 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4459 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 4462 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4463 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4464 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 wheel and tire. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt and detach the retainers. - To install, tighten to 12 Nm (106 lb-in). 4. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the 2 caliper anchor bolts and position the caliper, pads and anchor plate aside. - Support the caliper with mechanic's wire. - To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the front wheel speed sensor bolt and the sensor. - To install, tighten to 18 Nm (159 lb-in). 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4467 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. Remove the parking brake shoes. 2. Disconnect the wheel speed sensor harness from the retaining clips. 3. Remove the rear wheel speed sensor bolt and the sensor. - To install, tighten to 18 Nm (159 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4472 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. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4473 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4474 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. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4475 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. 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. 3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the brake pedal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4476 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Adjustable Pedals - Without Memory Feature Brake Pedal Assy: Description and Operation Adjustable Pedals - Without Memory Feature Adjustable Pedals Adjustable brake and accelerator pedals are available as an optional feature on this vehicle. The brake pedal position can be changed in phase with the accelerator pedal to increase driver comfort. Two different adjustable pedal systems are available; one that is connected to the memory feature option and one that is not connected to the memory feature option. Without Memory Feature Adjustable brake pedals without memory feature consist of the following components: - Adjustable brake pedal and bracket - Adjustable accelerator pedal and bracket, refer to Throttle Cable/Linkage - Adjustable pedal switch - Adjustable pedal motor - Adjustable pedal cables The pedals are adjusted through the use of a rocker switch mounted on the instrument panel. When the switch is pressed, voltage is sent to the motor which spins a cable that is attached to the adjustable brake pedal. As the cable spins, the pedals move either forward (away from the driver) or rearward (toward the driver) depending on how the switch is pressed. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Adjustable Pedals - Without Memory Feature > Page 4481 Brake Pedal Assy: Description and Operation Adjustable Pedals - With Memory Feature Adjustable Pedals Adjustable brake and accelerator pedals are available as an optional feature on this vehicle. The brake pedal position can be changed in phase with the accelerator pedal to increase driver comfort. Two different adjustable pedal systems are available; one that is connected to the memory feature option and one that is not connected to the memory feature option. With Memory Feature Adjustable brake and accelerator pedals are available as an optional feature on this vehicle. The brake pedal position can be changed in phase with the accelerator pedal to increase driver comfort. Two different adjustable pedal systems are available; one that is connected to the memory feature option and one that is not connected to the memory feature option. Adjustable brake pedals with memory feature consist of the following components: - Driver Seat Module (DSM), refer to Seats - Memory SET switch, refer to Seats - Remote Keyless Entry (RKE) transmitter, refer to Locks - Adjustable brake pedal and bracket - Adjustable accelerator pedal and bracket, refer to Throttle Cable/Linkage - Adjustable pedal switch - Adjustable pedal motor - Adjustable pedal cables The pedals are adjusted through the use of a rocker switch mounted on the instrument panel, the memory SET switch mounted on the seat trim panel or the door trim panel or the RKE transmitter. When the switch is pressed or the transmitter is activated, a voltage signal is sent to the DSM. The DSM then sends voltage to the adjustable pedal motor which spins a cable that is attached to the adjustable brake pedal. As the cable spins, the pedals move either forward (away from the driver) or rearward (toward the driver) depending on how the switch is pressed and/or current pedal position. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 4482 Brake Pedal Assy: Service and Repair Brake Pedal and Bracket NOTE: Adjustable brake pedal and bracket shown, fixed brake pedal and bracket similar. Removal and Installation Adjustable pedal vehicles 1. NOTICE: The brake pedal and the accelerator pedal must be in the same position when installing a new cable or a new pedal. The pedals must be all the way forward or all the way rearward or damage to components may occur. Disconnect the accelerator pedal-to-brake pedal cable from the adjustable brake pedal gear set. All vehicles 2. 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. 3. NOTE: An 11 mm, 12-point socket or wrench can be used to compress the 2 tabs on the brake pedal arm pin. Remove the brake pedal arm pin and disconnect the brake booster push rod from the brake pedal arm. 4. Remove the bulkhead sound insulator. 5. Remove the 4 brake pedal bracket nuts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 4483 - To install, tighten to 27 Nm (20 lb-ft). 6. Remove the 2 brake pedal bracket bolts and remove the brake pedal and bracket. - To install, tighten to 27 Nm (20 lb-ft). 7. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers > Page 4489 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 Expedition 2wd Workshop Manual (V8-5.4L (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. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4492 Brake Caliper: Removal and Replacement Brake Caliper Brake Caliper 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. 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 surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the brake pads. For additional information, refer to Brake Pads See: Brake Pad/Service and Repair/Front Disc Brake/Brake Pads. 2. Remove the brake caliper flow bolt and the 2 copper washers. - Discard the copper washers. - To install, tighten to 40 Nm (30 lb-ft). 3. Inspect the brake caliper for leaks. - If leaks are found, a new brake caliper must be installed. 4. To install, reverse the removal procedure. - Install new copper washers. 5. Bleed the brake caliper. Disc Brake System - Exploded View Disc Brake System - Exploded View Disc Brake System (view 1 of 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4493 Disc Brake System (view 2 of 2) 1. For additional information, refer to the procedures. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4494 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. 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 surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. If necessary, using a suitable suction device, remove the brake fluid from the master cylinder reservoir until it is half filled. 2. Remove the wheel and tire. 3. NOTICE: If the anchor housing spring is to be removed, do not force the spring off the brake caliper or damage to the spring may occur. NOTICE: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring may occur. Release the lower portion of the anchor housing spring. - Apply force to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 4. Rotate the spring upward and remove it from the brake caliper. 5. Rotate the outer brake pad upper and lower retaining springs to disengage them from the brake caliper anchor plate. 6. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may occur. Remove the 2 guide pin bushing caps, remove and discard the 2 brake caliper guide pin bolts and position the caliper aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4495 - Support the caliper using mechanic's wire. - Remove and discard the 2 brake caliper guide pin bushings. 7. Remove the 2 brake caliper anchor plate bolts and the anchor plate. Installation 1. Position the brake caliper anchor plate and install the 2 anchor plate bolts. - Tighten to 200 Nm (148 lb-ft). 2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. Install new brake hardware as follows: - Apply the specified lubricant to the inside of the guide pin bushings. - Install the guide pin bushings into the caliper bores. - Install the guide pins into the bushings. 3. NOTE: Make sure that the inner brake pad retaining springs are correctly seated onto the brake caliper anchor plate. Position the brake caliper assembly onto the anchor plate. 4. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. - Tighten the bolts to 55 Nm (41 lb-ft). 5. Rotate the outer brake pad upper and lower retaining springs until they are correctly seated on the anchor plate. 6. Install the anchor housing spring using the following procedure: 1. Insert the tab of the spring into the brake caliper cavity. 2. Twist the tab into the cavity. 7. NOTE: LH anchor housing spring shown, RH similar. Rotate the anchor housing spring and position the upper portion onto the anchor plate. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4496 8. NOTE: LH anchor housing spring shown, RH similar. Position the other anchor housing spring portion onto the anchor plate. 9. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. 10. NOTICE: The latch MUST be positioned as shown or damage to component may occur. Verify that the brake pad anti-rattle spring is correctly latched by pulling on the spring. 11. Fill the master cylinder with clean, specified brake fluid. 12. Install the wheel and tire. 13. Apply the brake several times to verify correct brake operation. Brake Caliper Brake Caliper 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. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4497 2. Remove the brake hose flow bolt and disconnect the hose. - Remove and discard the copper washers. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the 2 brake caliper guide pin caps and bolts. - Inspect the guide pin threads for damage, install a new guide pin(s) as necessary. - To install, tighten to 38 Nm (28 lb-ft). - Clean and dry guide pin threads as necessary. 4. Remove the brake caliper and remove the brake pads from the caliper. 5. Inspect the disc brake caliper dust boot for leaks and/or damage. - If leaks or damage are found, install a new brake caliper. 6. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. To install, reverse the removal procedure. - Install new guide pin bushings. - Apply supplied white lubricant to the inside of the guide pin bushings. 7. Bleed the brake caliper. Disc Brake System - Exploded View Disc Brake System - Exploded View Rear Brake Disc Components Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4498 1. For additional information, refer to the procedures. Brake Caliper Anchor Plate Brake Caliper Anchor Plate 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. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to 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 the fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. 3. NOTICE: Do not allow the caliper and brake pad assembly to hang from the brake hose or damage to the hose may occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. - Support the caliper using mechanic's wire. - Inspect the guide pin threads for damage and inspect the guide pin bushings for wear/damage. Install a new guide pin(s) and bushing(s) as necessary. - To install, tighten to 38 Nm (28 lb-ft). 4. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate. - Inspect the caliper anchor plate bolt threads for damage and foreign material. Install cleaned and dried anchor plate bolts or install new as necessary. - To install, tighten to 190 Nm (140 lb-ft). 5. Clean, dry and inspect the brake caliper anchor plate. Apply equal amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as indicated. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4499 6. Fill the master cylinder with clean, specified brake fluid. 7. To install, reverse the removal procedure. - Apply the brake several times to verify correct brake operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Brake pad minimum thickness.............................................................................................................. ........................................................2.0 mm (0.079 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4503 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Disc Brake System - Exploded View Disc Brake System - Exploded View Disc Brake System (view 1 of 2) Disc Brake System (view 2 of 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4506 1. For additional information, refer to the procedures. Brake Pads 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. 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 onto painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled on a painted or plastic surface, immediately wash the surface with water. 1. If necessary, using a suitable suction device, remove the brake fluid from the master cylinder reservoir until it is half filled. 2. Remove the wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4507 3. NOTICE: If the anchor housing spring is to be removed, do not force the spring off the brake caliper or damage to the spring may occur. NOTICE: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring may occur. Release the lower portion of the anchor housing spring. - Apply force to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 4. Rotate the spring upward and remove it from the brake caliper. 5. Rotate the outer brake pad upper and lower retaining springs to disengage them from the brake caliper anchor plate. 6. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may occur. Remove the 2 guide pin bushing caps, remove and discard the 2 brake caliper guide pin bolts and position the caliper aside. - Support the caliper using mechanic's wire. - Remove and discard the 2 brake caliper guide pin bushings. 7. Remove the 2 brake pads from the caliper. 8. Inspect the brake pads for wear and contamination, install new pads as necessary. 9. NOTICE: Protect the piston and boots when pushing the caliper piston into the caliper piston bores, or damage to the piston or boots may occur. If installing new brake pads, using a C-clamp and a worn brake pad, compress the brake caliper pistons into the caliper. 10. Inspect the brake disc and machine or install new as necessary. Installation 1. Clean the brake pad contact areas of the brake caliper. 2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. Install new brake hardware as follows: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4508 - Apply the specified lubricant to the inside of the guide pin bushings. - Install the guide pin bushings into the caliper bores. - Install the guide pin into the bushings. 3. Install the inboard brake pad onto the caliper. 4. Rotate the outer brake pad upper and lower retaining springs 90 degrees. 5. Remove the protective paper from the outboard brake pad and install it onto the brake caliper. 6. NOTE: Make sure that the inner brake pad retaining springs are correctly seated onto the brake caliper anchor plate. Position the brake caliper assembly onto the anchor plate. 7. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. - Tighten the bolts to 55 Nm (41 lb-ft). 8. Rotate the outer brake pad upper and lower retaining springs until they are correctly seated in the machined slot on the anchor plate. 9. Install the anchor housing spring using the following procedure: 1. Insert the tab of the spring into the brake caliper cavity. 2. Twist the tab into the cavity. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4509 10. NOTE: LH anchor housing spring shown, RH similar. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 11. NOTE: LH anchor housing spring shown, RH similar. Position the other anchor housing spring portion onto the anchor plate. 12. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. 13. NOTICE: The latch MUST be positioned as shown or damage to component may occur. Verify that the brake pad anti-rattle spring is correctly latched by pulling on the spring. 14. Fill the master cylinder with clean, specified brake fluid. 15. Install the wheel and tire. 16. Apply the brake several times to verify correct brake operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4510 Brake Pad: Service and Repair Rear Disc Brake Disc Brake System - Exploded View Disc Brake System - Exploded View Rear Brake Disc Components 1. For additional information, refer to the procedures. Brake Pads 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. Failure to follow these instructions may result in serious personal injury. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4511 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 onto painted or plastic surfaces or damage to 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 the fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. 3. NOTICE: Do not allow the brake caliper to hang by the flexible brake hose or damage to the hose may occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. - Support the caliper using mechanic's wire. - Remove and discard the guide pin bushings. - Inspect the guide pin threads for damage, install new guide pin(s) as necessary. 4. Remove the brake pads from the caliper. 5. Inspect the brake pads for wear or contamination and install new pads as necessary. 6. Using a C-clamp and a worn brake pad, press the piston into the caliper. 7. Inspect the brake disc and resurface or install a new brake disc as necessary. Installation 1. Clean, dry and inspect the brake caliper anchor plate. Apply equal amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as shown. 2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. Install new brake hardware as follows: - Apply equal amounts of the supplied white lubricant to the inside of the guide pin bushings. - Install the guide pin bushings into the caliper bores. - Install the guide pins into the bushings. 3. Install the brake pads to the caliper. 4. Position the caliper onto the anchor plate and install the 2 brake caliper guide pin bolts. - To install, tighten to 38 Nm (28 lb-ft). - Clean and dry guide pin threads as necessary. 5. Fill the master cylinder with clean, specified brake fluid. 6. Install the wheel and tire. 7. Apply the brake several times to verify correct brake operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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.................................................................................................... ......................................................32.0 mm (1.259 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front Brake Rotor/Disc > Page 4516 Brake Rotor/Disc: Specifications Rear Brake Rotor/Disc Rear Brake disc minimum thickness.................................................................................................... .......................................................20.0 mm (0.787 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4517 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 Expedition 2wd Workshop Manual (V8-5.4L (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. 12. Install the wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4520 Brake Rotor/Disc: Removal and Replacement Disc Brake System - Exploded View Disc Brake System - Exploded View Disc Brake System (view 1 of 2) Disc Brake System (view 2 of 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4521 1. For additional information, refer to the procedures. Brake Disc Brake Disc Removal and Installation 1. Remove the brake caliper anchor plate. For additional information, refer to Brake Caliper Anchor Plate See: Brake Caliper/Service and Repair/Removal and Replacement/Front Disc Brake/Brake Caliper Anchor Plate. 2. Remove the brake disc. 3. To install, reverse the removal procedure. 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 the brake disc shield screws. - To install, tighten to 17 Nm (150 lb-in). 3. Remove the brake disc shield. 4. To install, reverse the removal procedure. Disc Brake System - Exploded View Disc Brake System - Exploded View Rear Brake Disc Components Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4522 1. For additional information, refer to the procedures. Brake Disc Brake Disc Removal and Installation 1. Remove the wheel and tire. 2. NOTICE: Do not allow the brake caliper and anchor plate assembly to hang by the flexible brake hose or damage to the hose may occur. Remove the brake caliper anchor plate bolts and position the anchor plate and caliper assembly aside. - Support the caliper and anchor plate assembly with mechanic's wire. - Inspect the brake caliper anchor plate bolt threads for damage and foreign material. Install cleaned and dried anchor plate bolts or install new as necessary. - To install, tighten to 190 Nm (140 lb-ft). 3. NOTE: If the brake disc binds on the parking brake shoe, remove the adjustment hole access plug and contract the parking brake shoe. Remove the brake disc. 4. Inspect the brake disc and resurface or install a new brake disc as necessary. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Minimum Thickness.............................................................................................................................. ......................................................0.45 mm (0.02 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4532 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. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4533 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4534 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. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4535 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. 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. 3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the brake pedal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4536 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers > Page 4541 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 Expedition 2wd Workshop Manual (V8-5.4L (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. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4544 Brake Caliper: Removal and Replacement Brake Caliper Brake Caliper 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. 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 surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the brake pads. For additional information, refer to Brake Pads See: Disc Brake System/Brake Pad/Service and Repair/Front Disc Brake/Brake Pads. 2. Remove the brake caliper flow bolt and the 2 copper washers. - Discard the copper washers. - To install, tighten to 40 Nm (30 lb-ft). 3. Inspect the brake caliper for leaks. - If leaks are found, a new brake caliper must be installed. 4. To install, reverse the removal procedure. - Install new copper washers. 5. Bleed the brake caliper. Disc Brake System - Exploded View Disc Brake System - Exploded View Disc Brake System (view 1 of 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4545 Disc Brake System (view 2 of 2) 1. For additional information, refer to the procedures. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4546 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. 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 surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. If necessary, using a suitable suction device, remove the brake fluid from the master cylinder reservoir until it is half filled. 2. Remove the wheel and tire. 3. NOTICE: If the anchor housing spring is to be removed, do not force the spring off the brake caliper or damage to the spring may occur. NOTICE: Do not use any tools to remove the spring, use hand force only. Do not use excessive force or damage to the spring may occur. Release the lower portion of the anchor housing spring. - Apply force to the center of the spring and pull outward at the bottom of the spring to remove it from the lower brake caliper cavity. 4. Rotate the spring upward and remove it from the brake caliper. 5. Rotate the outer brake pad upper and lower retaining springs to disengage them from the brake caliper anchor plate. 6. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may occur. Remove the 2 guide pin bushing caps, remove and discard the 2 brake caliper guide pin bolts and position the caliper aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4547 - Support the caliper using mechanic's wire. - Remove and discard the 2 brake caliper guide pin bushings. 7. Remove the 2 brake caliper anchor plate bolts and the anchor plate. Installation 1. Position the brake caliper anchor plate and install the 2 anchor plate bolts. - Tighten to 200 Nm (148 lb-ft). 2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. Install new brake hardware as follows: - Apply the specified lubricant to the inside of the guide pin bushings. - Install the guide pin bushings into the caliper bores. - Install the guide pins into the bushings. 3. NOTE: Make sure that the inner brake pad retaining springs are correctly seated onto the brake caliper anchor plate. Position the brake caliper assembly onto the anchor plate. 4. Install the 2 brake caliper guide pin bolts and the 2 bushing caps. - Tighten the bolts to 55 Nm (41 lb-ft). 5. Rotate the outer brake pad upper and lower retaining springs until they are correctly seated on the anchor plate. 6. Install the anchor housing spring using the following procedure: 1. Insert the tab of the spring into the brake caliper cavity. 2. Twist the tab into the cavity. 7. NOTE: LH anchor housing spring shown, RH similar. Rotate the anchor housing spring and position the upper portion onto the anchor plate. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4548 8. NOTE: LH anchor housing spring shown, RH similar. Position the other anchor housing spring portion onto the anchor plate. 9. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. 10. NOTICE: The latch MUST be positioned as shown or damage to component may occur. Verify that the brake pad anti-rattle spring is correctly latched by pulling on the spring. 11. Fill the master cylinder with clean, specified brake fluid. 12. Install the wheel and tire. 13. Apply the brake several times to verify correct brake operation. Brake Caliper Brake Caliper 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. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4549 2. Remove the brake hose flow bolt and disconnect the hose. - Remove and discard the copper washers. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the 2 brake caliper guide pin caps and bolts. - Inspect the guide pin threads for damage, install a new guide pin(s) as necessary. - To install, tighten to 38 Nm (28 lb-ft). - Clean and dry guide pin threads as necessary. 4. Remove the brake caliper and remove the brake pads from the caliper. 5. Inspect the disc brake caliper dust boot for leaks and/or damage. - If leaks or damage are found, install a new brake caliper. 6. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. To install, reverse the removal procedure. - Install new guide pin bushings. - Apply supplied white lubricant to the inside of the guide pin bushings. 7. Bleed the brake caliper. Disc Brake System - Exploded View Disc Brake System - Exploded View Rear Brake Disc Components Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4550 1. For additional information, refer to the procedures. Brake Caliper Anchor Plate Brake Caliper Anchor Plate 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. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to 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 the fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. 3. NOTICE: Do not allow the caliper and brake pad assembly to hang from the brake hose or damage to the hose may occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. - Support the caliper using mechanic's wire. - Inspect the guide pin threads for damage and inspect the guide pin bushings for wear/damage. Install a new guide pin(s) and bushing(s) as necessary. - To install, tighten to 38 Nm (28 lb-ft). 4. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate. - Inspect the caliper anchor plate bolt threads for damage and foreign material. Install cleaned and dried anchor plate bolts or install new as necessary. - To install, tighten to 190 Nm (140 lb-ft). 5. Clean, dry and inspect the brake caliper anchor plate. Apply equal amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as indicated. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4551 6. Fill the master cylinder with clean, specified brake fluid. 7. To install, reverse the removal procedure. - Apply the brake several times to verify correct brake operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 P/N .............................................................................................................................................. .................................................................. PM-1-C Ford Specification ................................................................................................................................................... WSS-M6C62-A or WSS-M6C65-A1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4558 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4559 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Disc Brake System - Exploded View Disc Brake System - Exploded View Disc Brake System (view 1 of 2) Disc Brake System (view 2 of 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Disc Brake > Page 4565 1. For additional information, refer to the procedures. Brake Flexible Hose 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. 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 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. Detach the brake flexible hose retainer from the wheel speed sensor harness. 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 retaining clip. 5. Remove the brake caliper flow bolt and discard the 2 copper washers. - To install, tighten to 40 Nm (30 lb-ft). - Use new copper washers. 6. Remove brake flexible hose bracket bolt and brake flexible hose. - To install, tighten to 30 Nm (22 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Disc Brake > Page 4566 7. To install, reverse the removal procedure. - Bleed the brake caliper. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Disc Brake > Page 4567 Brake Hose/Line: Service and Repair Rear Disc Brake Disc Brake System - Exploded View Disc Brake System - Exploded View Rear Brake Disc Components 1. For additional information, refer to the procedures. Brake Flexible Hose Brake Flexible Hose Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Disc Brake > Page 4568 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. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to 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. - Install new copper washers. - To install, tighten to 40 Nm (30 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. - To install, tighten to 18 Nm (159 lb-in). 5. To install, reverse the removal procedure. - Bleed the brake caliper. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. 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. NOTE: On vehicles equipped with Roll Stability Control (RSC(R)), the ABS module and the Hydraulic Control Unit (HCU) are calibrated to one another. Do not swap ABS modules between RSC(R)-equipped vehicles. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 4572 NOTE: On vehicles equipped with RSC(R), the ABS module is available separately from the HCU and should be serviced separately. However, if the RSC(R)-equipped vehicle requires a new HCU, then the ABS module and the HCU must be installed as an assembly. Make sure to use the most recently released service parts. NOTE: When installing a new ABS module/HCU assembly, it must be configured (either by download/upload or uploading the as-built data method). 1. Disconnect the ABS module electrical connector. 2. NOTICE: Only authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and only authorized parts should be used when installing new inlet brake tubes. Use of other than authorized inlet brake tubes may result in damage to the components. NOTE: Plug each open port to prevent brake fluid from spilling. Disconnect the 6 brake tube fittings. - To install: Tighten the master cylinder brake tube fittings to 25 Nm (18 lb-ft). - Tighten the remaining brake tube fittings to 20 Nm (177 lb-in). 3. Remove the 3 HCU-to-bracket bolts and the HCU. - To install, tighten to 9 Nm (80 lb-in). 4. To install, reverse the removal procedure. - Bleed the brake system. 5. If installing a new ABS module/HCU assembly on a vehicle equipped with RSC(R), configure the ABS module. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 4577 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 Expedition 2wd Workshop Manual (V8-5.4L (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 4578 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 Expedition 2wd Workshop Manual (V8-5.4L (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 4579 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 Expedition 2wd Workshop Manual (V8-5.4L (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 4580 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. - 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. - 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 Expedition 2wd Workshop Manual (V8-5.4L (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 4581 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 Expedition 2wd Workshop Manual (V8-5.4L (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. 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. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4584 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4585 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. 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. Disconnect the brake fluid level switch. 2. Remove the air cleaner element. 3. Remove the 2 bolts and position the coolant expansion tank assembly aside. - To install, tighten bolts to 15 Nm (133 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4586 4. Loosen the brake tube fittings and disconnect the brake tubes. - Plug the master cylinder ports. - To install, tighten the fittings to 20 Nm (177 lb-in). 5. NOTICE: When the master cylinder is removed, the piston will be exposed. Do not damage the piston or piston surface or a fluid leak may occur. Remove the 2 brake master cylinder nuts and the brake master cylinder. - To install, tighten to 25 Nm (18 lb-ft). 6. To install, reverse the removal procedure. - Bleed the brake system. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 union 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. To reload the tension on the parking brake cable, follow the release procedure in reverse. - Make sure the cable tension is reloaded slowly. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4592 Parking Brake Cable: Removal and Replacement Parking Brake Cable - Rear, LH Parking Brake Cable - Rear, LH Removal and Installation 1. Relieve the tension on the parking brake cable system. For additional information, refer to Parking Brake Cable Tension Release See: Procedures. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Separate the LH rear cable from the equalizer. 4. Compress the 2 tabs and remove the conduit from the bracket. 5. NOTE: Be sure to correctly install the park brake cable retainer spring and route cables between suspension links. Disconnect the parking brake cable retainer spring from the cable. 6. Disconnect the LH rear cable from the retaining clip. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4593 7. Disconnect the ABS wheel speed sensor wire from the retaining clip. 8. Release the parking brake cable from the LH bracket assembly. 9. Release the cable from the parking brake actuating lever and remove the cable. 10. To install, reverse the removal procedure. Parking Brake Cable - Rear, RH Parking Brake Cable - Rear, RH Removal and Installation 1. Relieve the tension on the parking brake cable system. 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 RH rear cable from the cable union. 4. Compress the 2 tabs and release the conduit from the equalizer. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4594 5. Disconnect the RH rear cable from the retaining clip. 6. Remove the bolt and the wire form bracket from the LH side of the vehicle. - To install, tighten to 18 Nm (159 lb-in). 7. Remove the rear parking brake cable-to-crossmember bolt. - To install, tighten to 18 Nm (159 lb-in). 8. Remove the bolt and the wire form bracket from the RH side of the vehicle. - To install, tighten to 18 Nm (159 lb-in). 9. Release the parking brake cable from the RH bracket assembly. 10. Release the cable from the parking brake actuating lever and remove the cable. 11. To install, reverse the removal procedure. Parking Brake Cable - Front Parking Brake Cable - Front 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. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the front park brake cable P-clip-to-frame bolt. - To install, tighten to 18 Nm (159 lb-in). 4. Remove the front parking brake cable and conduit. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4595 - Pry the rubber seal from the front floor pan. - Compress the retainer and release the conduit from the bracket. - Remove the front cable and conduit from the cable union. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. Relieve tension on the parking brake cable system. For additional information, refer to Parking Brake Cable Tension Release See: Parking Brake Cable/Service and Repair/Procedures. 2. Remove the front door scuff plate. 3. Remove the instrument panel steering column opening trim panel and if equipped, the instrument panel lower cover. 4. Remove the parking brake release handle bolt. - To install, tighten to 3 Nm (27 lb-in). 5. Remove the retainer and the cowl trim panel. 6. Compress the 2 tabs and disconnect the parking brake release cable from the parking brake control assembly. 7. Disconnect the parking brake release cable from the release lever and remove the parking brake release handle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 4599 8. Disconnect the parking brake switch electrical connector. 9. Remove the 3 parking brake control assembly bolts. - To install, tighten to 20 Nm (177 lb-in). 10. Position the parking brake control assembly onto the floor. 11. Disconnect the parking brake cable from the take-up spool. 12. Compress the 2 tabs, disconnect the parking brake cable from the control assembly and remove the control assembly. 13. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments 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 0.45 mm (0.02 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4603 Parking Brake Shoe: Service and Repair Parking Brake Shoes Removal 1. Relieve the tension on the parking brake cable system. For additional information, refer to Parking Brake Cable Tension Release See: Parking Brake Cable/Service and Repair/Procedures. 2. Remove the brake disc. 3. Remove the front parking brake shoe retaining clip and pin. 4. Remove the parking brake shoe adjuster. - Using a suitable tool, spread the bottom of the parking brake shoes apart. - Remove the parking brake shoe adjuster. 5. Remove the parking brake shoe adjuster spring. 6. Slide the front parking brake shoe up and out of the guide flange. 7. Remove the front parking brake shoe. - Rotate the front parking brake shoe outward. - Remove the parking brake shoe return spring. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4604 8. Remove the rear parking brake shoe. - Remove the retaining clip and pin. - Remove the rear parking brake shoe. 9. Inspect the components for excessive wear or damage and install new parts as required. Installation 1. NOTICE: Apply the grease only where indicated, do not apply the grease to the parking brake shoes. The grease will contaminate the brake shoe linings and damage to the linings will result. Apply a light coat of the specified grease to the 6 parking brake shoe contact points on the disc brake shield. 2. Install the rear parking brake shoe. - Hold the rear parking brake shoe in position. - Install the retaining pin and clip. 3. Install the front parking brake shoe. - Install the parking brake shoe return spring to the rear parking brake shoe and to the front parking brake shoe. - Rotate the front parking brake shoe into the guide flange. 4. Slide the front parking brake shoe down into position on the flange. 5. Install the front parking brake shoe retaining pin and clip. 6. Install the parking brake shoe adjuster spring. 7. Install the parking brake shoe adjuster. - Using a suitable tool, spread the bottom of the parking brake shoes apart. - Install the parking brake shoe adjuster. 8. Adjust the parking brake shoes. For additional information, refer to Parking Brake Shoe Adjustment See: Adjustments. 9. NOTE: This step will require the aid of an assistant. Enable the parking brake cable system. - Pull down on the front parking brake cable at the coupler. - Remove the retaining pin from the parking brake lever. 10. Check the parking brake for correct operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4608 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4609 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations Brake Booster Vacuum Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4614 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4615 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4619 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Brake Booster > Page 4622 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. - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 4623 Vacuum Brake Booster: Service and Repair Brake Booster NOTE: Non-roll stability control equipped shown, roll stability control equipped similar. Removal and Installation All vehicles 1. Remove the air cleaner element. 2. Remove the 2 bolts and position the degas bottle/lower air cleaner housing assembly aside. - To install, tighten bolts to 15 Nm (133 lb-in). 3. Relieve the vacuum in the brake booster by pressing and releasing the brake pedal a minimum of 5 times with the engine not running. 4. Disconnect the brake fluid level switch. 5. NOTE: Support the master cylinder with mechanic's wire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 4624 Remove the 2 brake master cylinder nuts and position the master cylinder aside. - To install, tighten the nuts to 25 Nm (18 lb-ft). Vehicles equipped with Roll Stability Control (RSC(R)) 6. Disconnect the brake pedal travel solenoid electrical connector. All vehicles 7. Disconnect the brake pedal travel sensor electrical connector. 8. Disconnect the manifold vacuum outlet assembly from the brake booster. 9. 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. 10. Remove the brake pedal arm pin and disconnect the booster push rod from the brake pedal arm. 11. Remove the 4 brake booster-to-pedal bracket nuts and remove the brake booster. - To access the retaining nuts, fold back the sound insulation. - To install, tighten to 27 Nm (20 lb-ft). 12. 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. - For vehicles equipped with Roll Stability Control (RSC(R)), calibrate the ABS module. Follow the directions on the scan tool for the calibration procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 4629 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 4630 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4635 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4636 Electronic Brake Control Module: Diagrams Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4637 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4638 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4639 NOTE: On vehicles equipped with Roll Stability Control (RSC(R)), the ABS module and the Hydraulic Control Unit (HCU) are calibrated to one another. Do not swap ABS modules between RSC(R)-equipped vehicles. NOTE: On vehicles equipped with RSC(R), the ABS module is available separately from the HCU and should be serviced separately. However, if the RSC(R)-equipped vehicle requires a new HCU, then the ABS module and the HCU must be installed as an assembly. Make sure to use the most recently released service parts. NOTE: When installing a new ABS module/HCU assembly, it must be configured (either by download/upload or uploading the as-built data method). 1. Release the Air Cleaner (ACL) cover retaining clips and disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the ACL outlet clamp and disconnect the ACL cover from the outlet pipe. - To install, tighten to 4 Nm (35 lb-in). 3. Remove the 3 HCU bracket-to-frame bolts. - To install, tighten to 20 Nm (177 lb-in). 4. Disconnect the ABS module electrical connector. 5. Remove the 4 ABS module bolts and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 6. To install, reverse the removal procedure. 7. If installing a new ABS module on a vehicle equipped with RSC(R), configure the ABS module. 8. If installing a new ABS module on a vehicle equipped with RSC(R), calibrate the RSC(R) sensor. Connect the scan tool and carry out the IVD Initialization sequence. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 4643 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 4644 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations ABS Sensor Block: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 4649 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 4650 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Vehicles with floor shift 1. Remove the front floor console. 2. Remove the 4 bolts and the front floor console support bracket. - To install: Tighten the upper bolts to 9 Nm (80 lb-in). - Tighten the lower bolts to 40 Nm (30 lb-ft). Vehicles with column shift 3. Remove the stability control sensor cover. All vehicles 4. Disconnect the stability control sensor cluster electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 4654 5. Remove the 2 bolts and the stability control sensor cluster. - To install, tighten to 12 Nm (106 lb-in). 6. To install, reverse the removal procedure. - Connect the scan tool and carry out the IVD Initialization sequence. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4658 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4659 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4663 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4664 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4668 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4669 Ford Expedition 2wd Workshop Manual (V8-5.4L (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. Disconnect the steering wheel rotation sensor electrical connector. 2. Remove the 2 bolts and the steering wheel rotation sensor. - To install, tighten to 3 Nm (27 lb-in). 3. To install, reverse the removal procedure. 4. NOTE: If the sensor is not calibrated after installation, a DTC will be set in the ABS module. Calibrate the sensor in the following sequence: 1. Start the engine. 2. Rotate the steering wheel from lock to lock a minimum of 2 times. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 4676 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 4677 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 4682 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4683 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4684 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4685 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4686 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4687 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4688 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 4691 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4692 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4693 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 wheel and tire. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt and detach the retainers. - To install, tighten to 12 Nm (106 lb-in). 4. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the 2 caliper anchor bolts and position the caliper, pads and anchor plate aside. - Support the caliper with mechanic's wire. - To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the front wheel speed sensor bolt and the sensor. - To install, tighten to 18 Nm (159 lb-in). 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4696 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. Remove the parking brake shoes. 2. Disconnect the wheel speed sensor harness from the retaining clips. 3. Remove the rear wheel speed sensor bolt and the sensor. - To install, tighten to 18 Nm (159 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. If a new lock cylinder with keys is replaced, the new PATS keys must be programmed. 4. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4704 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 4710 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4713 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4714 Starter Relay: Testing and Inspection Run/Start Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4715 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair Battery Cables Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 4720 2. Disconnect the battery. For additional information, refer to Battery Disconnect See: Service and Repair/Battery Disconnect. 3. Remove the nut and position the battery ground cable terminal aside at the starter. - To install, tighten to 25 Nm (18 lb-ft). 4. Remove the nut and position the starter solenoid positive cable terminal aside. - To install, tighten to 12 Nm (106 lb-in). 5. Remove the nut and position the starter solenoid wire terminal aside. - To install, tighten to 5 Nm (44 lb-in). 6. Remove the 2 nuts and position the 2 battery cable harness brackets from the A/C compressor mounting bolts. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the bolt and position the battery ground cable-to-frame terminal aside. - To install, tighten to 25 Nm (18 lb-ft). 8. Remove the nut and position the generator harness terminal and the Battery Junction Box (BJB) cable terminal aside. - To install, tighten to 9 Nm (80 lb-in). 9. Remove the bolt and position the battery ground cable-to-cowl panel terminal aside. - To install, tighten to 12 Nm (106 lb-in). 10. Disconnect the battery cable harness in-line electrical connector, release the harness locator and remove the battery cable harness assembly. 11. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 4726 Alternator: Mechanical Specifications General Specifications Torque Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4727 Alternator: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4728 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4729 Alternator: Service and Repair Generator Removal and Installation NOTICE: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes. 1. Disconnect the battery. 2. For Navigator, release the 2 retainers and remove the engine cover. 3. Remove the Air Cleaner (ACL) intake pipe. 4. Rotate the Front End Accessory Drive (FEAD) belt tensioner counterclockwise and position the accessory drive belt aside. 5. Remove the harness locator from the generator bracket. 6. Remove the 4 bolts and the generator bracket. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the 2 bolts and position the generator aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4730 - Tighten to 25 Nm (18 lb-ft). 8. Disconnect the generator electrical connector. 9. Position the generator B+ protective cover aside, remove and discard the nut, then position the generator B+ terminal aside. - Install a new B+ terminal nut and tighten to 17 Nm (150 lb-in). 10. Remove the generator. 11. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the RUN position. Using a suitable tool, press the release pin and remove the ignition lock cylinder. 3. If a new lock cylinder with keys is replaced, the new PATS keys must be programmed. 4. To install, reverse the removal procedure. - Verify the ignition lock cylinder operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4737 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Key: Testing and Inspection Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Integrated Keyhead Transmitter (IKT) 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 and the vehicle does not start until 2 keys are programmed to the vehicle. This procedure also erases the Integrated Keyhead Transmitter (IKT) identification codes (TICs) from the Smart Junction Box (SJB), preventing the erased IKT from operating the Remote Keyless Entry (RKE) functions on the vehicle. NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS 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. One or both of them may be an IKT or a standard PATS key. 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 IC 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. Follow all Integrated Diagnostic System (IDS) screen instructions until the key erase procedure completes. The scan tool will also instruct to program 2 keys to complete the process. 4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be removed at this time). 5. NOTE: The RKE data transfer takes place between the key and the IC first. After both keys are programmed into the IC, the RKE data transfers from the IC to the SJB. Until the final data transfer takes place into the SJB, the RKE functions do not operate. NOTE: IKT keys require a 6-second programming time frame for the RKE data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the first PATS key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 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 a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 8. The vehicle should now start with both ignition keys and the RKE transmitter portion of an IKT should function. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4742 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 Instrument Cluster (IC) SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the 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. If the SPAREKEY PID reads DISABLED, the key programming using two programmed keys procedure cannot function. The switch is set to ENABLE when the vehicle is built. The switch does not affect the Key Programming Using Diagnostic Equipment procedure or the Spare Key Programming - Unlimited Key Mode procedure or the Spare Key Programming - Using Diagnostic Equipment procedure. 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, 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: "Customer Spare Key Programming Enable" (or "Customer Spare Key Programming Disable"). - "Customer Spare Key Programming Enable" - spare key programming procedure is accessible. - "Customer Spare Key Programming Disable" - spare key programming procedure is not accessible. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4743 Key: Testing and Inspection Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure works only if 2 or more programmed ignition keys are available. If 2 programmed keys are not available, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment. NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate. If this 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 PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the anti-theft indicator proves-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 portion 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 Instrument Cluster (IC) during this programming procedure, but only if the PID SPAREKEY is ENABLED. 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 PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure ends. 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 (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, 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 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, maintaining the key in the ON position for a minimum of 6 seconds (the additional 3 second time frame allows for the Remote Keyless Entry (RKE) data transfer to take place, if programming an Integrated Keyhead Transmitter (IKT) key). 6. Start the vehicle with the new key(s). 7. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4744 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 (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle. 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed to 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 PID UNL_KEY_ID 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 PID UNL_KEY_ID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. 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 . 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. 8. Insert the first Passive Anti-Theft System (PATS) key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an Integrated Keyhead Transmitter (IKT) key). 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 (6 seconds if it is an IKT key). 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4745 NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. 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 . 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. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 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 (6 seconds if it is an IKT key). 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 PID SPAREKEY 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 PID SPAREKEY must be enabled. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4746 Key: Testing and Inspection Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Integrated Keyhead Transmitter (IKT) 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 and the vehicle does not start until 2 keys are programmed to the vehicle. This procedure also erases the Integrated Keyhead Transmitter (IKT) identification codes (TICs) from the Smart Junction Box (SJB), preventing the erased IKT from operating the Remote Keyless Entry (RKE) functions on the vehicle. NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS 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. One or both of them may be an IKT or a standard PATS key. 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 IC 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. Follow all Integrated Diagnostic System (IDS) screen instructions until the key erase procedure completes. The scan tool will also instruct to program 2 keys to complete the process. 4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be removed at this time). 5. NOTE: The RKE data transfer takes place between the key and the IC first. After both keys are programmed into the IC, the RKE data transfers from the IC to the SJB. Until the final data transfer takes place into the SJB, the RKE functions do not operate. NOTE: IKT keys require a 6-second programming time frame for the RKE data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the first PATS key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 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 a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 8. The vehicle should now start with both ignition keys and the RKE transmitter portion of an IKT should function. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4747 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 Instrument Cluster (IC) SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the 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. If the SPAREKEY PID reads DISABLED, the key programming using two programmed keys procedure cannot function. The switch is set to ENABLE when the vehicle is built. The switch does not affect the Key Programming Using Diagnostic Equipment procedure or the Spare Key Programming - Unlimited Key Mode procedure or the Spare Key Programming - Using Diagnostic Equipment procedure. 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, 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: "Customer Spare Key Programming Enable" (or "Customer Spare Key Programming Disable"). - "Customer Spare Key Programming Enable" - spare key programming procedure is accessible. - "Customer Spare Key Programming Disable" - spare key programming procedure is not accessible. Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure works only if 2 or more programmed ignition keys are available. If 2 programmed keys are not available, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment. NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate. If this 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 PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the anti-theft indicator proves-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 portion 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 Instrument Cluster (IC) during this programming procedure, but only if the PID SPAREKEY is ENABLED. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4748 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 PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure ends. 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 (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, 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 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, maintaining the key in the ON position for a minimum of 6 seconds (the additional 3 second time frame allows for the Remote Keyless Entry (RKE) data transfer to take place, if programming an Integrated Keyhead Transmitter (IKT) key). 6. Start the vehicle with the new key(s). 7. 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. 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 (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle. 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed to 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4749 2. NOTE: If the PID UNL_KEY_ID 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 PID UNL_KEY_ID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. 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 . 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. 8. Insert the first Passive Anti-Theft System (PATS) key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an Integrated Keyhead Transmitter (IKT) key). 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 (6 seconds if it is an IKT key). 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, 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 . 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. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 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 (6 seconds if it is an IKT key). 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 PID SPAREKEY 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 PID SPAREKEY must be enabled. Spare Key Programming - Using Diagnostic Equipment Spare Key Programming - Using Diagnostic Equipment Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4750 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 Passive Anti-Theft System (PATS) keys to be programmed. The number of keys that are programmed into the PATS can be determined by viewing the Instrument Cluster (IC) PID N_KEYCODE. NOTE: When in the unlimited key mode (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, 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, 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". If the "ERASE" selection is made, all of the keys are erased from the system. From the scan tool menu select: "Program additional ignition key". 4. Turn the key to the OFF position and disconnect the scan tool. 5. Start the vehicle with the new PATS key. The vehicle starts 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 4751 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > General Specifications Starter Motor: Specifications General Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > General Specifications > Page 4756 Starter Motor: Specifications Torque Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4757 Starter Motor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4758 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4759 Starter Motor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4760 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4761 Starter Motor: Service and Repair Starter Motor Removal 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 terminal cover and remove the nut and the solenoid S-terminal electrical connection. 4. Remove the nut and the solenoid B-terminal electrical connection. 5. Remove the nut and the starter battery ground cable from the stud. 6. Remove the 2 bolts, the stud bolt and the starter motor. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4762 Installation 1. Position the starter and install the 2 bolts and the stud bolt in 3 stages. - Stage 1: Install the 2 starter bolts and the stud bolt finger-tight. - Stage 2: Tighten the upper bolt to 25 Nm (18 lb-ft). - Stage 3: Tighten the lower bolt and stud bolt to 25 Nm (18 lb-ft). 2. Position the starter battery ground cable onto the stud and install the nut. - Tighten to 25 Nm (18 lb-ft). 3. Connect the solenoid B-terminal electrical connection and install the nut. - Tighten to 12 Nm (106 lb-in). 4. Connect the solenoid S-terminal electrical connection and install the nut and the starter terminal cover. - Tighten to 6 Nm (53 lb-in). 5. Connect the battery ground cable. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay > Page 4767 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4770 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4771 Starter Relay: Testing and Inspection Run/Start Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4772 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 4778 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 4779 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 4780 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Instrument Panel and Console Auxiliary Power Outlet: Service and Repair Instrument Panel and Console 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Instrument Panel and Console > Page 4783 Auxiliary Power Outlet: Service and Repair Interior Trim and Ornamentation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Locations > Ignition Transformer Capacitor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Locations > Ignition Transformer Capacitor 1 > Page 4788 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 4791 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 4796 Fuse: Locations Passenger Compartment Fuse Panel Passenger Compartment Fuse Box 1 - 24 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 4797 25 - 48 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 4798 Fuse: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 4799 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 4800 Fuse: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 4801 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 4802 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 4805 Fuse: Application and ID Passenger Compartment Fuse Panel Passenger Compartment Fuse Box 1 - 24 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 4806 25 - 48 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 4807 Fuse: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 4808 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 4809 Fuse: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 4810 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 4811 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4816 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4817 Fuse Block: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4818 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4819 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4820 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4821 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 4822 Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 Fuse Block: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4855 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4856 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4857 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4858 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4859 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4860 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4861 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4862 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4863 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4864 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4865 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4866 Part 1 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4867 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4868 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4869 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4870 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4871 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4872 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4873 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4874 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4875 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4876 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4877 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4878 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4879 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4880 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4881 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4882 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4883 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4884 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4885 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4886 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4887 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4888 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4889 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4890 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4891 Multiple Junction Connector: Diagrams C411-C4002 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4892 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4893 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4894 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4895 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4896 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4897 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4898 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4899 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4900 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4901 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4902 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4903 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4904 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4905 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4906 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4907 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4908 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4909 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4910 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4911 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4912 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4913 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4914 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4915 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4916 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 4917 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data entry is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 devices are necessary to complete the configuration and turn off the flashing interior lights. 1. NOTE: This step is only necessary if the SJB is being replaced. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. A new SJB is delivered in a "manufacturing mode" with 7 pre-set DTCs. A successful configuration of the SJB, then a successful TPMS sensor training, then a successful self-test including the clearing of all DTCs is required in order to clear the 7 pre-set manufacturing mode DTCs. The 7 manufacturing mode DTCs are: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - 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) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the RH cowl panel side trim. 4. Remove the glove compartment. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 4921 1. Position the SJB and install the 2 bolts. - Tighten the bolts to 2 Nm (18 lb-in). 2. Connect the 7 electrical connectors. 3. Install the RH cowl panel side trim. 4. Install the glove compartment. 5. NOTE: If the SJB is not being replaced, this is the last step that is necessary. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears the DTCs B106D and B2477. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the SJB. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. 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. 8. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 9. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO Power Distribution Relay: Testing and Inspection Relay - Macro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4927 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4928 Power Distribution Relay: Testing and Inspection Relay - Micro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4929 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4930 Power Distribution Relay: Testing and Inspection Relay - Mini ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4931 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4932 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data entry is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 devices are necessary to complete the configuration and turn off the flashing interior lights. 1. NOTE: This step is only necessary if the SJB is being replaced. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. A new SJB is delivered in a "manufacturing mode" with 7 pre-set DTCs. A successful configuration of the SJB, then a successful TPMS sensor training, then a successful self-test including the clearing of all DTCs is required in order to clear the 7 pre-set manufacturing mode DTCs. The 7 manufacturing mode DTCs are: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - 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) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the RH cowl panel side trim. 4. Remove the glove compartment. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4937 1. Position the SJB and install the 2 bolts. - Tighten the bolts to 2 Nm (18 lb-in). 2. Connect the 7 electrical connectors. 3. Install the RH cowl panel side trim. 4. Install the glove compartment. 5. NOTE: If the SJB is not being replaced, this is the last step that is necessary. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears the DTCs B106D and B2477. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the SJB. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. 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. 8. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 9. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO Power Distribution Relay: Testing and Inspection Relay - Macro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4943 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4944 Power Distribution Relay: Testing and Inspection Relay - Micro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4945 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4946 Power Distribution Relay: Testing and Inspection Relay - Mini ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4947 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 4948 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 Relay Box: Locations Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4953 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4954 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4955 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4956 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4957 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4958 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4959 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4960 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4961 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4962 Ford Expedition 2wd Workshop Manual (V8-5.4L (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) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4965 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4966 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4967 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4968 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4969 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4970 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4971 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (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 4972 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Auxiliary Relay Box 2 > Page 4975 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Auxiliary Relay Box 2 > Page 4976 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Auxiliary Relay Box 2 > Page 4977 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Auxiliary Relay Box 2 > Page 4978 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 Relay Box: Locations Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4983 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4984 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4985 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4986 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4987 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4988 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4989 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4990 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4991 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 4992 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4995 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4996 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4997 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4998 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 4999 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5000 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5001 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5002 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5005 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5006 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5007 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5008 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 5014 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 5015 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 5016 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Instrument Panel and Console Auxiliary Power Outlet: Service and Repair Instrument Panel and Console 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Instrument Panel and Console > Page 5019 Auxiliary Power Outlet: Service and Repair Interior Trim and Ornamentation 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Locations > Ignition Transformer Capacitor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Locations > Ignition Transformer Capacitor 1 > Page 5024 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 5027 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 5032 Fuse: Locations Passenger Compartment Fuse Panel Passenger Compartment Fuse Box 1 - 24 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 5033 25 - 48 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 5034 Fuse: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 5035 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 5036 Fuse: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 5037 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Auxiliary Relay Box 2 > Page 5038 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5041 Fuse: Application and ID Passenger Compartment Fuse Panel Passenger Compartment Fuse Box 1 - 24 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5042 25 - 48 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5043 Fuse: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5044 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5045 Fuse: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5046 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5047 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5052 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5053 Fuse Block: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5054 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5055 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5056 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5057 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5058 Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 Fuse Block: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 Multiple Junction Connector: Diagrams C110-C410 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5091 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5092 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5093 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5094 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5095 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5096 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5097 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5098 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5099 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5100 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5101 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5102 Part 1 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5103 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5104 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5105 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5106 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5107 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5108 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5109 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5110 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5111 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5112 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5113 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5114 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5115 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5116 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5117 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5118 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5119 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5120 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5121 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5122 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5123 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5124 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5125 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5126 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5127 Multiple Junction Connector: Diagrams C411-C4002 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5128 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5129 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5130 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5131 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5132 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5133 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5134 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5135 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5136 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5137 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5138 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5139 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5140 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5141 Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5142 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5143 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5144 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5145 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5146 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5147 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5148 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5149 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5150 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5151 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5152 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5153 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data entry is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 devices are necessary to complete the configuration and turn off the flashing interior lights. 1. NOTE: This step is only necessary if the SJB is being replaced. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. A new SJB is delivered in a "manufacturing mode" with 7 pre-set DTCs. A successful configuration of the SJB, then a successful TPMS sensor training, then a successful self-test including the clearing of all DTCs is required in order to clear the 7 pre-set manufacturing mode DTCs. The 7 manufacturing mode DTCs are: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - 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) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the RH cowl panel side trim. 4. Remove the glove compartment. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5157 1. Position the SJB and install the 2 bolts. - Tighten the bolts to 2 Nm (18 lb-in). 2. Connect the 7 electrical connectors. 3. Install the RH cowl panel side trim. 4. Install the glove compartment. 5. NOTE: If the SJB is not being replaced, this is the last step that is necessary. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears the DTCs B106D and B2477. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the SJB. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. 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. 8. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 9. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO Power Distribution Relay: Testing and Inspection Relay - Macro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5163 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5164 Power Distribution Relay: Testing and Inspection Relay - Micro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5165 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5166 Power Distribution Relay: Testing and Inspection Relay - Mini ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5167 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5168 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. In the event that As-Built data entry is required (SJB will not communicate), all Remote Keyless Entry (RKE) devices must be programmed to the new SJB. A minimum of 2 devices are necessary to complete the configuration and turn off the flashing interior lights. 1. NOTE: This step is only necessary if the SJB is being replaced. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. A new SJB is delivered in a "manufacturing mode" with 7 pre-set DTCs. A successful configuration of the SJB, then a successful TPMS sensor training, then a successful self-test including the clearing of all DTCs is required in order to clear the 7 pre-set manufacturing mode DTCs. The 7 manufacturing mode DTCs are: - B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) - This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. - 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) Upload the module configuration information from the SJB into the scan tool. 2. Disconnect the battery. 3. Remove the RH cowl panel side trim. 4. Remove the glove compartment. 5. Disconnect the 7 electrical connectors. 6. Remove the 2 bolts and the SJB. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5173 1. Position the SJB and install the 2 bolts. - Tighten the bolts to 2 Nm (18 lb-in). 2. Connect the 7 electrical connectors. 3. Install the RH cowl panel side trim. 4. Install the glove compartment. 5. NOTE: If the SJB is not being replaced, this is the last step that is necessary. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears the DTCs B106D and B2477. The clearing of these DTCs indicates the calibration data has been successfully downloaded to the SJB. NOTE: DTC B2276 may be set, indicating there are less than 2 transmitters programmed to the SJB. Download the SJB configuration information from the scan tool to the SJB. 7. 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. 8. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. Carry out the SJB self-test (must include an on-demand self-test) and then repeat the self-test to confirm all DTCs have been cleared. 9. Rotate the instrument panel dimmer switch from the full dim position to the dome ON position. This will make sure that all displays are visible under all lighting conditions. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO Power Distribution Relay: Testing and Inspection Relay - Macro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5179 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5180 Power Distribution Relay: Testing and Inspection Relay - Micro ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5181 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5182 Power Distribution Relay: Testing and Inspection Relay - Mini ISO Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5183 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relay - Macro ISO > Page 5184 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 Relay Box: Locations Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5189 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5190 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5191 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5192 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5193 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5194 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5195 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5196 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5197 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5198 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5201 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5202 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5203 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5204 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5205 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5206 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5207 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5208 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5211 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5212 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5213 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5214 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 Relay Box: Locations Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5219 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5220 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5221 Relay Box: Locations Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5222 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5223 Relay Box: Locations Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5224 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5225 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5226 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5227 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Auxiliary Relay Box 2 > Page 5228 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5231 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5232 C2280B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5233 C2280B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5234 C2280C Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5235 C2280D Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5236 C2280D Part 2 C2280E Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5237 C2280F Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5238 C2280G Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5241 Relay Box: Application and ID Battery Junction Box (BJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5242 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5243 Relay Box: Application and ID Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Auxiliary Relay Box 2 > Page 5244 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Alignment Specifications Vehicles With Rear Coil Spring Suspension Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 5250 Alignment Specifications Vehicles With Rear Air Suspension Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 5251 Alignment: Specifications Ball Joint Deflection, Ride Height, and Vehicle Lean Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 5252 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 5253 Alignment: Specifications Torque Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 affect on tire wear. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5256 Alignment: Description and Operation Caster Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 does not affect tire wear. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5257 Alignment: Description and Operation Drift/Pull Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5258 Alignment: Description and Operation Nibble Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces or tire imbalance. This condition is observed by the driver as small rotational oscillations of the steering wheel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5259 Alignment: Description and Operation Camber Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 affect on tire wear. Caster Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 does not affect tire wear. Drift/Pull Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5260 - 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 Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces or tire imbalance. This condition is observed by the driver as small rotational oscillations of the steering wheel. Poor Groove Feel Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." - Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. - In the diagnosis of a steering or alignment concern, it is important to understand the difference between wander and poor groove feel. Poor Returnability/Sticky Steering Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 when the steering correction is completed. Shimmy Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 Wheel Alignment Angles Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5261 The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. Toe Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: - affects tire wear and directional stability. - must be checked after adding aftermarket equipment, such as a snowplow. Wander Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam bolt and nut. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement 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's arm until the scriber point is located in the center of the lower arm rearward 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's arm until the scriber point is located on the lower surface of the wheel knuckle near the ball joint. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 5264 5. Subtract measurement 3 from measurement 2 to obtain the front ride height. - For additional information, 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 rearward bolt (measurement 2). 2. Measure the distance between the flat level surface and the center of the shock absorber lower bolt (rearward side) (measurement 3). 3. Subtract measurement 3 from measurement 2 to obtain the rear ride height. - For additional information, refer to Specifications. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 5265 Alignment: Service and Repair Camber And Caster Adjustment - Front Camber and Caster Adjustment - Front NOTICE: Do not remove the stabilizer bar brackets until the stabilizer links have been disconnected or damage to the stabilizer bar links may occur. NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. NOTE: To allow for adjustment of the lower arm in the frame slots, the lower arm bolts and nuts must be removed and discarded. They are replaced with cam bolt kit 3C333. The vehicle should be supported by the frame to ease movement of the lower arm in the slot. 1. Using alignment equipment and the manufacturers instructions, measure the front caster and camber. - Refer to Alignment Specifications in the Specifications portion for optimal alignment settings. - If the caster and camber values are not within specification, go to the next step. 2. Remove and discard the lower arm front and rear nuts and bolts. 3. NOTICE: Do not hold the stabilizer link boot with any tool, as damage to the boot will occur. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nuts. Remove and discard the stabilizer bar link lower nuts. 4. Remove the 4 stabilizer bar bracket nuts, 2 stabilizer bar brackets and position the stabilizer bar aside. 5. Remove the stabilizer bar bracket bolts and plate assembly. 6. Install the front cam bolt kit and loosely install the nut. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 5266 7. Install the rear cam bolt kit and loosely install the nut. 8. To adjust the caster and camber, refer to the following chart. - Adjustments that require moving the front and the rear of the lower arm should be made equally. 9. With the weight of the vehicle resting on the wheel and tire assemblies, hold the front cam bolt and tighten the nut to 350 Nm (258 lb-ft). 10. With the weight of the vehicle resting on the wheel and tire assemblies, hold the rear cam bolt and tighten the nut to 350 Nm (258 lb-ft). 11. Install the 2 stabilizer bar bracket bolts and plate assembly. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 5267 12. Position the stabilizer bar, install the 2 stabilizer bar brackets and the 4 stabilizer bar bracket nuts. - Tighten the nuts to 55 Nm (41 lb-ft). 13. NOTICE: Do not hold the stabilizer link boot with any tool, as damage to the boot will occur. NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nuts. Install the 2 stabilizer bar link lower nuts. - Tighten the nuts to 80 Nm (59 lb-ft). 14. Check and, if necessary, adjust the front toe. For additional information, refer to Toe Adjustment - Front See: Toe Adjustment - Front. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 5268 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. 1. Using alignment equipment and the manufacturer's instructions, measure the front toe. - Refer to Alignment Specifications in the Specifications portion for optimal alignment settings. - If the front toe values are not within specification, go to the next step. 2. Start the engine and center the steering wheel. 3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the straight-ahead position. 4. Remove the steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). 6. NOTE: Do not allow the steering gear bellows to twist while rotating the tie rod. Rotate the tie rod(s) to achieve the desired toe setting. 7. NOTICE: Make sure to hold the tie-rod end stationary while tightening the jam nut or damage to the boot may occur. NOTE: Make sure that the toe settings are not disturbed while tightening the jam nuts. Tighten the tie-rod end jam nut(s) to 103 Nm (76 lb-ft). 8. Install the steering gear bellows clamp(s). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 5269 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 5270 Alignment: Service and Repair Toe Adjustment - Rear Toe Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear toe. NOTE: Before carrying out a toe adjustment, check the tires for the correct pressure. Inspect the tires for incorrect wear or damage. Inspect the suspension for wear or damage. 1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. - Refer to Alignment Specifications in the Specifications portion for optimal alignment settings. - If the rear toe values are not within specification, go to the next step. 2. Loosen the toe link cam bolt nut(s). 3. Rotate the toe link cam bolt(s) until the toe setting is within specification. 4. NOTE: Make sure the toe settings are not disturbed while tightening the cam nut(s). Tighten the toe link cam bolt nut(s) to 275 Nm (203 lb-ft). 5. Recheck the rear toe setting, adjust as necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Ride Height Measurement > Page 5271 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear camber or toe. NOTE: Before carrying out a camber adjustment, check the tires for the correct pressure. Inspect the tires for incorrect wear or damage. Inspect the suspension for wear or damage. 1. Using alignment equipment and the manufacturer's instructions, measure the rear camber. - Refer to Alignment Specifications in the Specifications portion for optimal alignment settings. - If the rear camber value is not within specification, go to the next step. 2. Remove the upper arm-to-frame bolt and the camber set shim. - Discard the camber set shim. - Install and snug the upper arm-to frame bolt. 3. Position the upper arm-to-frame bolt in the upper arm-to-frame slot until the camber setting is within specification. 4. NOTE: Do not allow the upper arm to move and change the camber adjustment setting when tightening the bolt. Tighten the upper arm-to-frame bolt to 225 Nm (166 lb-ft). 5. Recheck the camber setting, adjust as necessary. 6. Check and, if necessary, adjust the rear toe. For additional information, refer to Toe Adjustment Rear See: Toe Adjustment - Rear. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 5280 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 5281 Suspension Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 5282 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 5283 Suspension Control Module: Service and Repair Vehicle Dynamics Module (VDM) Removal and Installation NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. NOTE: The Vehicle Dynamics Module (VDM) is mounted to the lower left side of the dash above the parking brake control. Disconnect the 2 VDM electrical connectors. 2. Remove the VDM bracket nuts and the module. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: The VDM is calibrated with information from the ride height sensors. A new or exchanged VDM requires that the LH and RH ride height sensors are calibrated and a Pneumatic Test is carried out. For additional information, refer to Vehicle Dynamic Suspension See: Suspension/Suspension Control ( Automatic - Electronic )/Testing and Inspection Calibration Initialize System - Clear C1990 and C1991 DTCs. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5289 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5290 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5293 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5297 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5298 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Locations > Page 5302 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Locations > Page 5306 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair Ride Height Sensor: Service and Repair Suspension Height Sensor LH Side RH Side Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Page 5311 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the height sensor harness from the sensor bracket. 3. Disconnect the height sensor electrical connector. 4. Disconnect the height sensor arm from the ball stud on the lower control arm. 5. Remove and discard the 2 height sensor bolts. - To install, tighten to 11 Nm (97 lb-in). 6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the LH and RH height sensors. For additional information, refer to Ride Height Adjustments See: Suspension/Suspension Control ( Automatic - Electronic )/Service and Repair/Ride Height Adjustments. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5315 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5316 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5322 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5323 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5326 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5327 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5328 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5329 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering 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 parts, 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 bearing and wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub See: Suspension/Wheel Bearing/Service and Repair/Front Suspension. 2. Remove and discard the tie-rod end nut. 3. Using the Ball Joint Separator, separate the tie-rod end from the wheel knuckle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5334 4. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 5. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link lower nut. 6. Remove and discard the shock absorber lower nut and bolt. 7. Remove and discard the upper ball joint nut. 8. NOTE: Be sure not to damage the ball joint boot when installing the Ball Joint Separator. Using the Ball Joint Separator, separate the upper ball joint from the wheel knuckle. 9. Remove and discard the lower ball joint nut. 10. NOTICE: Make sure to use the Ball Joint Separator when separating the lower ball joint from the knuckle to prevent damage to the ball joint boot. Using the Ball Joint Separator, separate the lower ball joint from the wheel knuckle. 11. If necessary, remove the 3 brake disc shield bolts and remove the brake disc shield. Installation NOTICE: Do not tighten the lower shock nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load and bushing damage may occur. 1. If necessary, install the brake disc shield and the 3 brake disc shield bolts. - Tighten to 17 Nm (150 lb-in). 2. Position the lower ball joint into the wheel knuckle and install the new lower ball joint nut. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5335 - Tighten to 150 Nm (111 lb-ft). 3. Position the upper ball joint into the wheel knuckle and install the new upper ball joint nut. - Tighten to 115 Nm (85 lb-ft). 4. NOTE: Do not tighten the nut at this time. Loosely install the new shock absorber lower nut and bolt. 5. NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nut. Position the stabilizer bar link and install the new stabilizer bar link lower nut. - Tighten to 80 Nm (59 lb-ft). 6. Position the wheel speed sensor harness bracket and install the wheel speed sensor harness bracket bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the tie-rod end and install the new tie-rod end nut. - Tighten to 115 Nm (85 lb-ft). 8. Install the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub See: Suspension/Wheel Bearing/Service and Repair/Front Suspension. 9. With the weight of the vehicle on the wheel and tire, tighten the shock absorber lower nut to 550 Nm (406 lb-ft). 10. Check and, if necessary, align the front end. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 5340 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation Power Steering Fluid Cooler: Description and Operation Air Conditioning A/C Condenser/Power Steering Combo Cooler The A/C condenser/power steering combo cooler 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. The receiver/drier is incorporated onto the LH side of the condenser core. The receiver/drier cartridge is a separate component and can be removed and installed separately from the condenser core. The top portion of the condenser/power steering combo cooler is partitioned from the refrigerant system and is used for power steering fluid cooling. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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. Remove the upper air deflector. 1. Remove the 10 upper air deflector pin-type retainers. 2. Remove the air deflector. 2. Remove the air cleaner element. 3. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 4. Release the clamp and disconnect the power steering fluid cooler-to-power steering fluid reservoir hose. 5. Release the clamp and disconnect the power steering fluid reservoir-to-pump supply hose. 6. Remove the power steering fluid reservoir bolt and reservoir. - To install, tighten to 7 Nm (62 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 5350 7. To install, reverse the removal procedure. 8. Fill the power steering system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose Power Steering Line/Hose: Service and Repair Steering Gear To Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose 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. Remove the upper air deflector. 1. Remove the 10 upper air deflector pin-type retainers. 2. Remove the air deflector. 3. Remove the air cleaner outlet pipe. 4. Release the clamp and disconnect the power steering gear-to-fluid cooler return hose from the power steering fluid cooler. 5. Release the lower cooling fan shroud tab and rotate the shroud upward. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose > Page 5355 6. Remove the 2 bolts and the oil drip shield. - To install, tighten to 7 Nm (62 lb-in). 7. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering gear-to-fluid cooler return hose. - To install, tighten to 23 Nm (17 lb-ft). 8. To install, reverse the removal procedure. 9. Fill the power steering system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose > Page 5356 Power Steering Line/Hose: Service and Repair Power Steering Pump To Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line 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. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley See: Power Steering Pump/Service and Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose > Page 5357 Repair/Power Steering Pump Pulley. 2. Remove the 2 bolts and the oil drip shield. - To install, tighten to 7 Nm (62 lb-in). 3. Disconnect the power steering pressure line-to-power steering pump fitting. - To install, tighten to 65 Nm (48 lb-ft). 4. Disconnect the Power Steering Pressure (PSP) switch electrical connector. 5. Remove the power steering pressure line bracket-to-crossmember bolt. - To install, tighten to 7 Nm (62 lb-in). 6. Remove the power steering pressure line bracket-to-engine nut. - To install, tighten to 40 Nm (30 lb-ft). 7. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering pressure line. - To install, tighten to 23 Nm (17 lb-ft). 8. To install, reverse the removal procedure. 9. Fill the power steering system. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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. NOTE: A new Teflon(R) seal must be installed any time the line is disconnected from the power steering pump. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5362 1. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley See: Power Steering Pump Pulley. 2. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 3. Release the clamp and disconnect the power steering fluid reservoir-to-pump supply hose. 4. Remove the power steering pressure line bracket-to-engine nut. - To install, tighten to 40 Nm (30 lb-ft). 5. Disconnect the power steering pressure line-to-power steering pump fitting. - Discard the Teflon(R) seal. - To install, tighten to 65 Nm (48 lb-ft). 6. Remove the 3 bolts and the power steering pump. - To install, tighten to 25 Nm (18 lb-ft). 7. To install, reverse the removal procedure. - Using the Teflon(R) Seal Installer Set, install a new Teflon(R) seal on the pressure line-to-pump fitting. 8. Fill the power steering system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5363 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the upper air deflector. 1. Remove the 10 upper air deflector pin-type retainers. 2. Remove the air deflector. 3. Remove the air cleaner outlet pipe. 4. NOTE: LH shown, RH similar. Remove the 2 upper cooling fan shroud bolts and the wiring harness retainers. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5364 5. Release the lower cooling fan shroud tab and rotate the shroud upwards. 6. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the power steering pump pulley. 7. Position the cooling fan shroud assembly upward to gain clearance to install the Power Steering Pump Pulley Remover. 8. Using the Power Steering Pump Pulley Remover, remove the power steering pump pulley. Installation 1. NOTE: If the pulley has been removed and installed twice, install a new power steering pump pulley. NOTE: Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a new pulley. If there is 1 paint mark or none at all, use a paint pencil to mark the web area of the pulley near the hub. Using the Power Steering Pump Pulley Installer, install the power steering pump pulley. 2. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt to the power steering pump pulley. 3. Lower the cooling fan shroud assembly. - Release the lower cooling fan shroud tab, rotate the shroud downward. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5365 4. NOTE: LH shown, RH similar. Install the 2 upper cooling fan shroud bolts and the wiring harness retainers. - Tighten to 10 Nm (89 lb-in). 5. Install the air cleaner outlet pipe. 6. Install the upper air deflector and the 10 pin-type retainers. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5370 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5371 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5374 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5378 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5379 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Telescoping Wheel Switch > Component Information > Locations > Page 5383 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Tilt Wheel Switch > Component Information > Locations > Page 5387 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 5391 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 5392 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 switch 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 portion 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. Make sure that all SRS components are connected. 2. Turn the ignition switch from OFF to ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5398 3. Install RCM fuse 32 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will illuminate 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. The flashing might not occur until approximately 30 seconds after the ignition 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 a 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 using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5399 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 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: 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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 portion 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. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column to allow for steering column upper and lower shroud removal. 9. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to the left from the straight-ahead position to access the driver air bag module wire clips and to prevent damage to the steering column multi-function switch. Failure to follow this instruction may result in component damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5400 Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position) as shown. 10. Remove the lower steering column opening cover. - Remove the 3 screws. - Pull out to release the top retainers. - Remove the lower steering column opening cover. If equipped, disconnect the adjustable pedals switch connector. 11. If equipped, remove the screw and steering column manual tilt lever. 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 15. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel. Failure to follow this instruction may result in component damage and/or system failure. NOTE: Steering wheel is removed for clarity. The rear of the steering wheel is shown. NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5401 16. NOTE: Once the driver air bag module is removed, note the position of the 2 driver air bag module locator pins on the steering wheel for installation. Disconnect the driver air bag module and horn switch electrical connectors and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight-ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door to allow access to the passenger air bag electrical connector. - If equipped, disconnect the glove compartment door dampener. 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat. The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical. 21. Release the RH second row safety belt retractor D-ring cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5402 22. Remove the bolt and the RH second row safety belt retractor D-ring. 23. Remove the cover and the RH C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the RH C-pillar trim panel. 25. Disconnect the RH safety canopy module electrical connector. 26. Release the LH second row safety belt retractor D-ring cover. 27. Remove the bolt and the LH second row safety belt retractor D-ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5403 28. Remove the cover and the LH C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver C-pillar trim panel. 30. Disconnect the LH safety canopy module electrical connector. 31. NOTE: There are 2 similar connectors under the driver seat. The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the Smart Junction Box (SJB). 33. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 32 (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 install the driver front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5404 4. Connect the LH safety canopy module electrical connector. 5. Install the LH C-pillar trim panel and attach the rear door weatherstrip. 6. Install the LH C-pillar trim panel nut and cover. 7. Install the LH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the LH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the RH safety canopy module electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5405 10. Install the RH C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger C-pillar trim panel nut and cover. 12. Install the RH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 13. Attach the RH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Extract and retract the safety belt between the full extension and stowed positions. - If excessive effort or binding is present, install a new safety belt buckle retractor and tongue assembly as necessary. For additional information, refer to Seat Belt Systems. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5406 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. NOTICE: The clockspring 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 horn switch and 2 driver air bag module electrical connectors. 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. NOTE: Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. 23. If equipped, install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. If equipped, connect the adjustable pedals switch connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5407 25. Install the lower steering column opening cover and 3 screws. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 32 (10A) to the SJB and install the cover. 28. 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. 29. 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 air bag SRS fault is present, the air bag warning indicator will either: - fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate 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 will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the RCM using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Telescoping Wheel Motor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Telescoping Wheel Motor > Component Information > Locations > Page 5411 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Telescoping Wheel Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Telescoping Wheel Switch > Component Information > Locations > Page 5415 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Motor > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Motor > Component Information > Locations > Page 5419 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Motor > Component Information > Locations > Page 5420 Tilt Wheel Motor: Service and Repair Steering Column Motor Removal and Installation 1. Remove the steering column. For additional information, refer to Steering Column See: Service and Repair/Removal and Replacement/Steering Column. 2. Remove the screw and the ignition switch. - To install, tighten to 5 Nm (44 lb-in). 3. Remove the roll pin from the steering column motor. 4. Remove the bolt and the motor. - To install, tighten to 25 Nm (18 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Switch > Component Information > Locations > Page 5424 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Steering Gear: Service and Repair Steering Gear Steering Gear 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5429 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTICE: Do not allow the steering column shaft to rotate while disconnected from the gear or damage to the clockspring may occur. If there is evidence that the steering column shaft has rotated, the clockspring must be recentered. For additional information, refer to Air Bag Systems. Hold the steering wheel in the straight ahead position using a suitable holding device. 3. Remove and discard the outer tie-rod end nuts. 4. NOTICE: Use care when installing the Ball Joint Tool Separator or damage to the tie-rod end boot may occur. Using the Ball Joint Tool Separator, disconnect the tie-rod ends from the wheel knuckles. 5. Release the lower cooling fan shroud tab and rotate the shroud upward. 6. Remove the 2 bolts and the oil drip shield. 7. NOTICE: Do not allow the steering column shaft to rotate while it is disconnected from the steering gear or damage to the clockspring may result. If there is evidence that the steering column shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems. Remove the steering column shaft-to-steering gear bolt and disconnect the steering column shaft from the steering gear. 8. NOTICE: New O-ring seals must be installed any time the lines are disconnected from the steering gear or a fluid leak may occur. Remove the power steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering lines. - Discard the O-ring seals. 9. Remove the 2 steering gear-to-crossmember bolts and remove the steering gear. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5430 - Discard the bolts. Installation 1. NOTICE: Make sure the LH steering gear bushing is seated correctly or failure of the steering gear may occur. The RH side bushing does not have locking tabs. Position the steering gear and install the 2 steering gear-to-crossmember bolts. - Tighten the new bolts to 440 Nm (325 lb-ft). 2. Connect the steering column shaft and install the bolt. - Tighten to 30 Nm (22 lb-ft). 3. NOTE: New O-ring seals must be installed any time the line is disconnected from the power steering gear. Connect the steering lines, rotate the clamp plate and install the clamp plate bolt. - Tighten to 23 Nm (17 lb-ft). 4. Install the oil drip shield and the 2 bolts. - Tighten to 7 Nm (62 lb-in). 5. Release the lower cooling fan shroud tab and rotate the shroud downward. 6. NOTICE: Make sure that the tie-rod end boots are seated correctly on the tie-rod ends or tie-rod end failure may occur. Connect the tie-rod ends to the wheel knuckles and install the nuts. - Tighten the new nuts to 115 Nm (85 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5431 7. Fill the power steering system. 8. Check and, if necessary, adjust the front toe. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5432 Steering Gear: Service and Repair Steering Gear Turn Tubes Steering Gear Turn Tubes 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. If equipped, remove the 4 skid plate bolts and the skid plate. - To install, tighten to 25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5433 3. Release the lower cooling fan shroud position tab and rotate the shroud upwards until the lower tab locks into position. 4. NOTICE: New O-ring seals must be installed any time the lines are disconnected from the steering gear or a leak may occur. Remove the steering gear turn tubes clamp plate bolt. - Discard the O-ring seals. - To install, tighten to 11 Nm (97 lb-in). 5. NOTICE: Inspect the banjo bolt damper seals for wear or damage and install new seals as necessary. Remove the 2 banjo bolt dampers and the steering gear turn tubes. - To install, tighten to 33 Nm (24 lb-ft). 6. To install, reverse the removal procedure. 7. Fill the power steering system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair Steering Shaft: Service and Repair Steering Column Shaft Removal and Installation 1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 2. 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. NOTICE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be recentered. For additional information, refer to Air Bag Systems. Remove the bolt and disconnect the upper steering column shaft from the steering column. Discard the bolt. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Page 5437 - To install, tighten the new bolt to 30 Nm (22 lb-ft). 4. Remove the bolt and disconnect the upper steering column shaft from the lower steering column shaft. - Discard the bolt. - To install, tighten the new bolt to 48 Nm (35 lb-ft). 5. Remove the 2 bolts, the dash seal and the upper steering column shaft. - To install, tighten to 12 Nm (106 lb-in). 6. Remove the bolt and disconnect the lower steering column shaft from the steering gear. - Discard the bolt. - To install, tighten the new bolt to 30 Nm (22 lb-ft). 7. WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel Switch, Left Steering Wheel: Locations Steering Wheel Switch, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel Switch, Left > Page 5442 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel Switch, Left > Page 5443 Steering Wheel: Locations Steering Wheel Switch, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Steering Wheel Switch, Left > Page 5444 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Steering Wheel Switch, Left Steering Wheel: Diagrams Steering Wheel Switch, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Steering Wheel Switch, Left > Page 5447 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Steering Wheel Switch, Left > Page 5448 Steering Wheel: Diagrams Steering Wheel Switch, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Steering Wheel Switch, Left > Page 5449 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams > Page 5450 Steering Wheel: Service and Repair Steering Wheel Removal and Installation 1. Remove the driver air bag module. For additional information, refer to Air Bag Systems. 2. Turn the steering wheel to the straight-ahead position. 3. Remove and discard the steering wheel bolt. - To install, tighten the new bolt to 40 Nm (30 lb-ft). 4. Disconnect the steering wheel switches electrical connector from the clockspring. 5. Remove the steering wheel while routing the wires from the clockspring through the steering wheel. 6. Tape the clockspring center rotor to the outer housing to keep it from rotating. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair Tie Rod: Service and Repair Inner Tie Rod Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 5454 Removal NOTICE: The steering gear bellows 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: If present, the orientation of the vent tube must be noted so the boots and vent tubes may be installed in the correct location. Incorrect venting may lead to internal component damage. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen the tie-rod end jam nut. 3. Remove and discard the outer tie-rod end nut. 4. NOTICE: Use care when installing the Ball Joint Tool Separator or damage to the tie-rod end boot may occur. Using the Ball Joint Tool Separator, disconnect 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 outer tie-rod end. 6. Remove the tie-rod end jam nut. 7. NOTE: New bellows boot clamps must be installed. Remove and discard the inner and outer bellows boot clamp. 8. Remove the steering gear bellows boot. 9. NOTE: 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. 10. NOTICE: Thoroughly remove any abrasive material from steering gear components. 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. Using an appropriate-sized crowfoot wrench, install the inner tie rod. - Tighten to 120 Nm (89 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 5455 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. 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. NOTICE: Make sure that the tie-rod end boots are seated correctly on the tie-rod ends or failure may occur. Connect the tie-rod end to the wheel knuckle and install a new tie-rod end nut. - Tighten to 115 Nm (85 lb-ft). 8. Tighten the tie-rod end jam nut. - Tighten to 103 Nm (76 lb-ft). 9. Check and, if necessary, adjust the front toe. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Ball Joint: Service and Repair Front Suspension Ball Joint - Lower Removal 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Front Steering Knuckle/Service and Repair. 2. Remove and discard the lower ball joint snap ring. 3. Using the C-Frame and Screw Installer/Remover and the Ball Joint Remover, remove the lower ball joint. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 5462 Installation 1. NOTICE: Do not damage the lower ball joint boot when installing the C-Frame and Screw Installer/Remover and the Ball Joint Installer/Remover or premature failure of the ball joint may occur. NOTE: Make sure the ball joint snap ring is fully seated. Using the C-Frame and Screw Installer/Remover and the Ball Joint Installer/Remover, install the lower ball joint. - Install the ball joint snap ring. 2. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Front Steering Knuckle/Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 5463 Ball Joint: Service and Repair Rear Suspension Ball Joint - Lower 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 correct retention of these parts. 1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Rear Knuckle/Service and Repair/Wheel Knuckle. 2. Remove and discard the ball joint snap ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 5464 3. Using the C-Frame and Screw Installer/Remover and the Ball Joint Installer/Remover, remove the ball joint. Installation 1. NOTICE: Do not damage the ball joint boot when installing the special tool. NOTE: Clean and inspect the ball joint bore for bore damage before installing a new ball joint. Using the C-Frame and Screw Installer/Remover and the Ball Joint Installer/Remover, install the ball joint. 2. NOTE: Always use a new ball joint snap ring. Install a new snap ring. 3. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Rear Knuckle/Service and Repair/Wheel Knuckle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Rear Suspension 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 correct retention of these parts. NOTE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. 1. Remove the wheel and tire. 2. If equipped, disconnect the air suspension height sensor connecting link from the lower arm. 3. Remove and discard the shock absorber lower bolt and flagnut. 4. Remove and discard the lower arm-to-frame bolt and flagnut. 5. Remove and discard the lower ball joint nut. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Rear Suspension > Page 5469 6. NOTICE: Do not damage the ball joint boot while installing the Ball Joint Separator. Using the Ball Joint Separator, separate the lower ball joint from the wheel knuckle. 7. Swing the lower arm to the rear of the vehicle and remove the lower arm. Installation 1. Position the lower arm ball joint onto the wheel knuckle and install the new lower ball joint nut. - Tighten to 150 Nm (111 lb-ft). 2. NOTE: Do not tighten the lower arm-to-frame bolt at this time. Install the new lower arm-to-frame bolt and flagnut. - Snug the bolt to 50 Nm (37 lb-ft). 3. 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. 4. Install the wheel and tire. 5. Lower the vehicle so that the weight of the vehicle is on the wheel and tire assemblies. 6. Tighten the lower arm-to-frame bolt to 225 Nm (166 lb-ft). 7. Tighten the shock absorber lower bolt to 550 Nm (406 lb-ft). 8. If equipped, connect the air suspension height sensor connecting link to the lower arm. 9. Check and, if necessary, align the rear end. Upper Arm Upper Arm Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Rear Suspension > Page 5470 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 correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the upper arm-to-wheel knuckle nut. 3. Using the Ball Joint Separator, separate the upper arm from the wheel knuckle. 4. Remove and discard the upper arm-to-frame bolt, washer, camber set shim and flagnut. 5. Remove the upper arm. Installation 1. NOTE: Do not tighten the nut at this time. Install the upper arm and loosely install the new upper arm-to-frame bolt, washer, camber set shim and flagnut. 2. NOTE: Do not tighten the nut at this time. Loosely install the new upper arm-to-wheel knuckle nut. 3. Install the wheel and tire. 4. With the weight of the vehicle on the wheel and tires, tighten the upper arm-to-frame bolt to 225 Nm (166 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Rear Suspension > Page 5471 5. With the weight of the vehicle on the wheel and tires, tighten the upper arm-to-wheel knuckle nut to 103 Nm (76 lb-ft). 6. Check and, if necessary, adjust the rear alignment. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Rear Suspension > Page 5472 Control Arm: Service and Repair Front Suspension - Rear Wheel Drive (RWD) 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 parts, 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Rear Suspension > Page 5473 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. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link lower nut. 4. Remove and discard the lower ball joint nut. 5. NOTICE: Make sure to use the Ball Joint Separator when separating the lower ball joint from the knuckle to prevent damage to the ball joint boot. Using the Ball Joint Separator, separate the ball joint from the knuckle. 6. Remove and discard the lower arm rearward nut and bolt. 7. Remove and discard the lower arm forward nut and bolt. 8. Remove the shock absorber lower nut, bolt and the lower arm. - Discard the shock absorber lower nut and bolt. Installation 1. Position the lower arm and loosely install the new shock absorber lower bolt and nut. 2. Loosely install the new lower arm forward nut and bolt. 3. Loosely install the new lower arm rearward nut and bolt. 4. Position the lower ball joint into the wheel knuckle and install the new lower ball joint nut. - Tighten to 150 Nm (111 lb-ft). 5. Install the new stabilizer bar link lower nut. - Tighten to 80 Nm (59 lb-ft). 6. 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). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Rear Suspension > Page 5474 7. NOTE: Use a crowfoot wrench to tighten the lower arm rearward nut. Tighten the lower arm rearward nut to 350 Nm (258 lb-ft). 8. Tighten the lower arm forward nut to 350 Nm (258 lb-ft). 9. Tighten the shock absorber lower nut to 550 Nm (406 lb-ft). 10. Install the wheel and tire. 11. Check and, if necessary, align the front end. Upper Arm Upper 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 parts, 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). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Rear Suspension > Page 5475 2. 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/Front Suspension - Rear Wheel Drive (RWD). 3. Remove and discard the upper ball joint nut. 4. Using the Ball Joint Separator, separate the upper ball joint from the wheel knuckle. 5. Remove the upper arm-to-frame nuts and bolts and the upper arm. - Discard the bolts. Installation 1. NOTE: Do not tighten the nuts at this time. Position the upper arm and loosely install the new upper arm-to-frame bolts and nuts. 2. Position the ball joint into the wheel knuckle and install the new upper ball joint nut. - Tighten to 115 Nm (85 lb-ft). 3. 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). 4. Tighten the upper arm-to-frame nuts to 150 Nm (111 lb-ft). 5. Install the shock absorber and spring assembly. For additional information, refer to Shock Absorber and Spring Assembly See: Suspension Strut / Shock Absorber/Service and Repair/Front Suspension - Rear Wheel Drive (RWD). 6. Check and, if necessary, align the front end. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair Transmission Support Crossmember Removal and Installation Transmission Support Crossmember - Exploded View NOTE: Transmission not shown for clarity. Transmission Support Crossmember - Exploded View 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the skid plate fasteners and skid plate. 3. Remove the LH and RH exhaust heat shield-to-crossmember fasteners. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Page 5479 4. Remove the 2 transmission mount nuts. - To install, tighten to 103 Nm (76 lb-ft). 5. Support the transmission. 6. NOTE: - Mark the transmission crossmember next to the edge of the frame bracket to make sure the crossmember is installed in the same position it was removed from. - The crossmember nuts are installed on the crossmember bolts facing the front of the vehicle. Remove the 4 transmission crossmember bolts (2 each side) and the transmission crossmember. To install, tighten to 90 Nm (66 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Page 5480 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering 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 parts, 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 bearing and wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Front Suspension. 2. Remove and discard the tie-rod end nut. 3. Using the Ball Joint Separator, separate the tie-rod end from the wheel knuckle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 5484 4. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 5. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link lower nut. 6. Remove and discard the shock absorber lower nut and bolt. 7. Remove and discard the upper ball joint nut. 8. NOTE: Be sure not to damage the ball joint boot when installing the Ball Joint Separator. Using the Ball Joint Separator, separate the upper ball joint from the wheel knuckle. 9. Remove and discard the lower ball joint nut. 10. NOTICE: Make sure to use the Ball Joint Separator when separating the lower ball joint from the knuckle to prevent damage to the ball joint boot. Using the Ball Joint Separator, separate the lower ball joint from the wheel knuckle. 11. If necessary, remove the 3 brake disc shield bolts and remove the brake disc shield. Installation NOTICE: Do not tighten the lower shock nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load and bushing damage may occur. 1. If necessary, install the brake disc shield and the 3 brake disc shield bolts. - Tighten to 17 Nm (150 lb-in). 2. Position the lower ball joint into the wheel knuckle and install the new lower ball joint nut. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 5485 - Tighten to 150 Nm (111 lb-ft). 3. Position the upper ball joint into the wheel knuckle and install the new upper ball joint nut. - Tighten to 115 Nm (85 lb-ft). 4. NOTE: Do not tighten the nut at this time. Loosely install the new shock absorber lower nut and bolt. 5. NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nut. Position the stabilizer bar link and install the new stabilizer bar link lower nut. - Tighten to 80 Nm (59 lb-ft). 6. Position the wheel speed sensor harness bracket and install the wheel speed sensor harness bracket bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the tie-rod end and install the new tie-rod end nut. - Tighten to 115 Nm (85 lb-ft). 8. Install the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Front Suspension. 9. With the weight of the vehicle on the wheel and tire, tighten the shock absorber lower nut to 550 Nm (406 lb-ft). 10. Check and, if necessary, align the front end. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing Rear Knuckle: Service and Repair Wheel Knuckle Bushing Wheel Knuckle Bushing 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 5490 replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the upper trailing arm-to-wheel knuckle bolt. - Position the upper trailing arm upward to access the wheel knuckle bushing. 3. Using the Bearings and Washers Forcing Screw, the Bushing Remover and the Bushing Remover/Installer, remove the wheel knuckle bushing. Installation 1. Clean and inspect the wheel knuckle bushing bore for damage or excessive wear. 2. Position the new wheel knuckle bushing with the larger void facing towards the upper trailing arm. 3. Install the Bearings and Washers Forcing Screw, the Bushing Remover and the Bushing Remover/Installer. 4. NOTE: Do not use the forward forcing screw nut to install the bushing. The forward forcing screw nut is only used to correctly position and align the bushing for installation. Hand tighten the forward forcing screw nut to align the bushing with the rearward side of the wheel knuckle bore. 5. NOTICE: Use the rearward forcing screw nut to install the bushing or damage to the bushing and/or the wheel knuckle bushing bore may result. Tighten the rearward forcing screw nut and install the bushing until it is centered in the wheel knuckle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 5491 6. NOTE: After installing the wheel knuckle bushing, make sure to measure the bushing position in the wheel knuckle bore. The measurement from the bushings outer metal surface to the machined face surface of knuckle bore should be 2.54 mm (0.16 in) +/- 0.25 mm (0.01 in). If necessary, use the Bearings and Washers Forcing Screw, the Bushing Remover and the Bushing Remover/Installer to adjust the bushing position in the wheel knuckle bushing bore. 7. NOTE: Do not tighten the trailing arm-to-wheel knuckle bolt at this time. Connect the upper trailing arm-to-the wheel knuckle and loosely install the bolt. 8. Install the wheel and tire. 9. Lower the vehicle so that the weight of the vehicle is resting on the wheel and tires. 10. Tighten the new upper trailing arm-to-the wheel knuckle bolt to 250 Nm (184 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 5492 Rear Knuckle: Service and Repair Wheel Knuckle 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 replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the wheel bearing and wheel hub assembly. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Rear Suspension. 2. Remove the parking brake shoes. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 5493 3. Remove the brake disc shield. 4. Compress the spring and depress the retaining tabs and detach the parking brake cable from the wheel knuckle and parking brake lever. 5. Remove and discard the upper arm-to-wheel knuckle nut. 6. Using the Ball Joint Separator, separate the upper arm from the wheel knuckle. 7. Remove and discard the lower ball joint nut. 8. Using the Ball Joint Separator, separate the lower ball joint from the wheel knuckle. 9. Remove and discard the 2 bolts and disconnect the lower trailing arm from the wheel knuckle. 10. Remove and discard the bolt and disconnect the toe link from the wheel knuckle. 11. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Using the hex-holding feature, remove and discard the stabilizer bar link nut and disconnect the link from the wheel knuckle. 12. Remove the upper trailing arm-to-wheel knuckle bolt and the wheel knuckle. - Discard the bolt. Installation 1. NOTE: Do not tighten the upper trailing arm-to wheel knuckle bolt at this time. Position the wheel knuckle and loosely install the new upper trailing arm-to-wheel knuckle bolt. 2. Connect the stabilizer bar link to the wheel knuckle and install the new nut. - Tighten to 63 Nm (46 lb-ft). 3. NOTE: Do not tighten the toe link-to-wheel knuckle bolt at this time. Connect the toe link-to-the wheel knuckle and loosely install the new bolt. 4. Connect the lower trailing arm to the wheel knuckle and install the 2 new bolts. - Tighten to 103 Nm (76 lb-ft). 5. Position the lower ball joint onto the wheel knuckle and install the new lower ball joint nut. - Tighten to 150 Nm (111 lb-ft). 6. Position the upper arm and install the new upper arm-to-wheel knuckle nut. - Tighten the nut to 103 Nm (76 lb-ft). 7. Compress the spring, insert the retaining tabs and attach the parking brake cable to the wheel knuckle and parking brake cable lever. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Wheel Knuckle Bushing > Page 5494 8. Install the brake disc shield. 9. Install the parking brake shoes. 10. Install the wheel bearing and wheel hub assembly. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Rear Suspension. 11. Lower the vehicle so that the weight of the vehicle is resting on the wheel and tires. 12. Tighten the toe link-to-the wheel knuckle bolt to 225 Nm (166 lb-ft). 13. Tighten the upper trailing arm-to-wheel knuckle bolt to 250 Nm (184 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 correct retention of these parts. 1. Remove the wheel and tire. 2. Index-mark the cam bolt and cam washer positions. 3. Remove and discard the toe link-to-wheel knuckle bolt and washer. 4. Remove and discard the toe link-to-frame cam bolt, cam washer and nut. 5. Remove the toe link. Installation 1. Using the index marks made in removal Step 2, transfer the marks onto the new cam bolt and cam washer. 2. NOTE: Do not tighten the nut at this time. Align the index marks and loosely install the new toe link-to-wheel knuckle bolt and washer. 3. NOTE: Do not tighten the bolt at this time. Loosely install the new toe link-to-frame cam bolt, cam washer and nut. 4. Install the wheel and tire. 5. Lower the vehicle so that the weight of the vehicle is resting on the wheel and tires. 6. Tighten the toe link-to-wheel knuckle bolt to 225 Nm (166 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Page 5498 7. Align the index marks and tighten the toe link-to-frame cam nut to 275 Nm (203 lb-ft). 8. Check and, if necessary, adjust the rear toe. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 5506 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 5507 Suspension Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 5508 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 5509 Suspension Control Module: Service and Repair Vehicle Dynamics Module (VDM) Removal and Installation NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. NOTE: The Vehicle Dynamics Module (VDM) is mounted to the lower left side of the dash above the parking brake control. Disconnect the 2 VDM electrical connectors. 2. Remove the VDM bracket nuts and the module. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: The VDM is calibrated with information from the ride height sensors. A new or exchanged VDM requires that the LH and RH ride height sensors are calibrated and a Pneumatic Test is carried out. For additional information, refer to Vehicle Dynamic Suspension See: Suspension Control ( Automatic - Electronic )/Testing and Inspection Calibration Initialize System - Clear C1990 and C1991 DTCs. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair Ride Height Sensor: Service and Repair Suspension Height Sensor LH Side RH Side Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Page 5514 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the height sensor harness from the sensor bracket. 3. Disconnect the height sensor electrical connector. 4. Disconnect the height sensor arm from the ball stud on the lower control arm. 5. Remove and discard the 2 height sensor bolts. - To install, tighten to 11 Nm (97 lb-in). 6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the LH and RH height sensors. For additional information, refer to Ride Height Adjustments See: Suspension Control ( Automatic Electronic )/Service and Repair/Ride Height Adjustments. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5518 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5519 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: LH side shown, RH side similar. 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 parts, 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. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nut. Remove and discard the 2 stabilizer bar link upper nuts. - To install, tighten the new nuts to 80 Nm (59 lb-ft). 3. NOTICE: Do not hold the stabilizer link boot with any tool as damage to the boot will occur. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Remove and discard the 2 stabilizer bar link lower nuts and remove the 2 stabilizer bar links. - To install, tighten the new nuts to 80 Nm (59 lb-ft). 4. Remove the 4 stabilizer bar bracket nuts, brackets and the stabilizer bar. - Discard the nuts. - To install, tighten the new nuts to 55 Nm (41 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5525 5. Remove and discard the stabilizer bracket bolt plates. 6. NOTE: Make sure the stabilizer bar bushing upset is installed into the bracket groove. Inspect and, if necessary, install new stabilizer bar bushings. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5526 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Bar and Link NOTE: RH side shown, LH side similar. 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 correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque. Remove the 4 stabilizer bar link nuts and the links. - Discard the nuts. - Remove the stone shields. - To install, tighten the new nuts to 63 Nm (46 lb-ft). 3. Remove the 4 stabilizer bar bracket nuts, the 2 stabilizer bar brackets and the stabilizer bar. - Discard the nuts. - To install, tighten the new nuts to 48 Nm (35 lb-ft). 4. NOTE: Inspect and, if necessary, install new stabilizer bar bushings. NOTE: The rear stabilizer bar must be installed with the center hump facing downward. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 5527 NOTE: The rear stabilizer bar bushings must be installed outboard of the upset rings on the stabilizer bar. NOTE: The stabilizer bar link stone shields must be installed on the stabilizer bar attachment point. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Service and Repair Air Dryer: Service and Repair Air Suspension Compressor Drier Removal and Installation 1. Remove the air compressor. For additional information, refer to Air Suspension Compressor See: Compressor/Pump/Service and Repair. 2. Remove the compressor drier screw. - To install, tighten to 3 Nm (27 lb-in). 3. NOTE: Make sure that the drier O-ring does not remain inside of the compressor assembly. Rotate the compressor drier 90 degrees counterclockwise to unlock, then remove the air compressor drier. 4. NOTE: Inspect the compressor drier O-ring for damage and install a new O-ring as necessary. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Technical Service Bulletins > Customer Interest for Air Spring: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Air Spring: Customer Interest Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. 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 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Spring: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Air Spring: All Technical Service Bulletins Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. 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 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Page 5548 Compressor/Pump: Service and Repair Air Suspension Compressor Removal and Installation WARNING: Vent all air pressure from the air suspension system prior to disconnecting or removing any air suspension components. It is dangerous to remove air suspension components while under pressure. Failure to follow this instruction may result in serious personal injury. 1. Remove the inner fender splash shield. 2. Disconnect the air line from the compressor drier. - Compress the quick connect lock ring inward, then pull the line outward from the air drier. 3. Disconnect the air compressor air intake hose. 4. Disconnect the air compressor electrical connector. 5. Remove the 3 air compressor bracket bolts and remove the air compressor and bracket assembly. - To install, tighten to 15 Nm (133 lb-in). 6. NOTE: When installing the air lines, make sure the white inner air line is fully inserted into the fitting for correct installation. NOTE: Make sure that there are no objects trapped under or on the bracket. Make sure that the air compressor is not in contact with any surrounding components that could cause vibration noises. NOTE: Make sure that the air compressor moves freely in the rubber isolators. Make sure that the bracket has no deformations that could cause the 3 rubber isolators to load against each other. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Customer Interest for Level Control Solenoid Valve: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Level Control Solenoid Valve: Customer Interest Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. 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 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Level Control Solenoid Valve: > 08-24-7 > Dec > 08 > Suspension - Rear Load Leveling Leak Down Level Control Solenoid Valve: All Technical Service Bulletins Suspension - Rear Load Leveling Leak Down TSB 08-24-7 12/08/08 REAR LOAD LEVELING LEAKS DOWN IN EXTREME COLD WEATHER FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigators vehicles equipped with rear load leveling suspension, may exhibit air suspension leak down on one or both rear corners after extended periods of time in temperatures of -22 degrees Fahrenheit (-30 degrees Celsius) or below. The leak down is the result of premature wear of solenoid seat at low temperatures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Determine that concern occurs at -22 degrees Fahrenheit (-30 degrees Celsius) or below, after sitting long periods of time, usually over night. If concern does not occur under these conditions, do not continue with this procedure. The concern may not be duplicated if the vehicle has been sitting inside for over 15 minutes. Replace the air spring solenoid valve per Workshop Manual, Section 204-05: Vehicle Dynamic Suspension. 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 082407A 2007-2009 Expedition, 0.5 Hr. Navigator: Replace ONE Rear Air Spring Solenoid. (Do Not Use With 5300A9 5300A, 12650D) 082407B 2007-2009 Expedition, 0.6 Hr. Navigator: Replace BOTH Rear Air Spring Solenoids. (Do Not Use With 5300A9 5300A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 3B486 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Locations > Air Spring Solenoid Valve, Left Rear Level Control Solenoid Valve: Locations Air Spring Solenoid Valve, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Locations > Air Spring Solenoid Valve, Left Rear > Page 5567 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Locations > Air Spring Solenoid Valve, Left Rear > Page 5568 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Locations > Air Spring Solenoid Valve, Left Rear > Page 5569 Level Control Solenoid Valve: Locations Air Spring Solenoid Valve, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Locations > Air Spring Solenoid Valve, Left Rear > Page 5570 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Diagrams > Air Spring Solenoid Valve, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Diagrams > Air Spring Solenoid Valve, Left Rear > Page 5573 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Diagrams > Page 5574 Level Control Solenoid Valve: Service and Repair Air Spring Solenoid Valve Removal and Installation 1. If the air spring solenoid valve is functional, use the scan tool to vent the appropriate air spring(s). 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Disconnect the air spring solenoid valve electrical connector. 4. Disconnect the air line at the air valve. - Compress the orange quick connect lock ring, then pull downward on the air supply line. 5. NOTICE: Remove any dirt or other foreign material from the air spring assembly prior to removing the air spring solenoid valve from the air spring assembly, or damage to the solenoid valve and air spring may occur. Remove the air spring solenoid clip. 6. WARNING: Vent all air pressure from the air suspension system prior to disconnecting or removing any air suspension components. It is dangerous to remove air suspension components while under pressure. Failure to follow this instruction may result in serious personal injury. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Diagrams > Page 5575 The air spring solenoid valve has a 2-stage release. Vent the air spring using the following procedure: 1. Carefully rotate the air spring solenoid counterclockwise until it reaches the first stage and allow the air in the spring to completely vent. 2. Rotate the solenoid counterclockwise to the second stage and remove the solenoid. 7. NOTE: Inspect the air spring O-ring for damage and install a new O-ring as necessary. Lightly lubricate the solenoid seal area with silicone grease. NOTE: After installing the solenoid, it is necessary to inflate the air suspension system. For additional information, refer to Ride Height Adjustments See: Service and Repair/Ride Height Adjustments. NOTE: When installing the air spring solenoid, make sure that the electrical connector is positioned away from the air spring. NOTE: When installing the air lines, make sure the air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Service and Repair Ride Height Sensor: Service and Repair Suspension Height Sensor LH Side RH Side Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Page 5579 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the height sensor harness from the sensor bracket. 3. Disconnect the height sensor electrical connector. 4. Disconnect the height sensor arm from the ball stud on the lower control arm. 5. Remove and discard the 2 height sensor bolts. - To install, tighten to 11 Nm (97 lb-in). 6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the LH and RH height sensors. For additional information, refer to Ride Height Adjustments See: Service and Repair/Ride Height Adjustments. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 5583 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 5584 Suspension Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 5585 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 5586 Suspension Control Module: Service and Repair Vehicle Dynamics Module (VDM) Removal and Installation NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. NOTE: The Vehicle Dynamics Module (VDM) is mounted to the lower left side of the dash above the parking brake control. Disconnect the 2 VDM electrical connectors. 2. Remove the VDM bracket nuts and the module. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: The VDM is calibrated with information from the ride height sensors. A new or exchanged VDM requires that the LH and RH ride height sensors are calibrated and a Pneumatic Test is carried out. For additional information, refer to Vehicle Dynamic Suspension See: Testing and Inspection Calibration Initialize System - Clear C1990 and C1991 DTCs. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) Suspension Spring ( Coil / Leaf ): Service and Repair Front Suspension - Rear Wheel Drive (RWD) Shock Absorber and Spring Assembly Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5591 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 parts, 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 and discard the shock absorber upper mount nuts. 2. Remove the wheel and tire. 3. Remove and discard the tie-rod end nut. 4. Using the Ball Joint Separator, separate the tie-rod end from the wheel knuckle. 5. Detach the flexible hose retainer from the speed sensor harness. 6. Remove the brake flexible hose bracket bolt and disconnect the bracket from the wheel knuckle. 7. Remove and discard the upper ball joint nut. 8. Remove and discard the shock absorber lower nut and bolt. 9. Using the Ball Joint Separator, disconnect the upper arm ball joint from the wheel knuckle and remove the shock absorber and spring assembly. 10. NOTE: If the individual spring and/or shock components are not being serviced, continue to the Installation procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5592 NOTE: For reference during assembly, index-mark the upper mount, spring and shock absorber. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 11. NOTE: Use the hex-holding feature to prevent the shock rod from turning while removing the nut. While holding the shock rod, remove the nut and the shock absorber. - Discard the nut. 12. Remove the upper mount, dust boot and insulator. Installation NOTICE: Do not tighten the lower shock nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load and bushing damage may occur. 1. Position the shock absorber and spring and install the dust boot, insulator and the upper mount. 2. NOTE: Align the index marks made during disassembly. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. NOTE: Use the hex-holding feature to prevent the shock rod from turning while installing the nut. Using the hex-holding feature to hold the shock rod, install the shock absorber and the shock rod nut. - Tighten the new nut to 56 Nm (41 lb-ft). 4. Install the shock absorber and spring assembly and connect the upper arm ball joint to the wheel knuckle. - Tighten the new nut to 115 Nm (85 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5593 5. NOTE: Do not tighten the nut at this time. Loosely install the new shock absorber lower nut and bolt. 6. Connect the brake flexible hose bracket to the wheel knuckle and install the bolt. - Tighten the bolt to 30 Nm (22 lb-ft). 7. Attach the flexible hose retainer to the speed sensor harness. 8. Install the tie-rod end nut. - Tighten to 150 Nm (111 lb-ft). 9. Install the wheel and tire. 10. Install the new shock absorber upper mount nuts. - Tighten to 40 Nm (30 lb-ft). 11. With the weight of the vehicle on the wheel and tire, tighten the shock absorber lower nut to 550 Nm (406 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5594 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Shock Absorber and Spring Assembly 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 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 shock absorber upper mount nuts. - To install, tighten the new nuts to 40 Nm (30 lb-ft). 3. Remove the shock absorber and spring assembly. 4. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step 7. NOTE: For reference during assembly, index-mark the upper mount, spring and shock absorber. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5595 5. While holding the shock rod, remove the nut and washer. - Remove the shock absorber. - Discard the nut. - To install, tighten the new nut to 56 Nm (41 lb-ft). 6. Remove the upper mount, dust boot and insulator. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber and Spring Assembly 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 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 shock absorber upper mount nuts. - To install, tighten the new nuts to 40 Nm (30 lb-ft). 3. Remove the shock absorber and spring assembly. 4. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step 7. NOTE: For reference during assembly, index-mark the upper mount, spring and shock absorber. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension > Page 5600 5. While holding the shock rod, remove the nut and washer. - Remove the shock absorber. - Discard the nut. - To install, tighten the new nut to 56 Nm (41 lb-ft). 6. Remove the upper mount, dust boot and insulator. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension > Page 5601 Suspension Strut / Shock Absorber: Service and Repair Front Suspension - Rear Wheel Drive (RWD) Shock Absorber and Spring Assembly Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension > Page 5602 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 parts, 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 and discard the shock absorber upper mount nuts. 2. Remove the wheel and tire. 3. Remove and discard the tie-rod end nut. 4. Using the Ball Joint Separator, separate the tie-rod end from the wheel knuckle. 5. Detach the flexible hose retainer from the speed sensor harness. 6. Remove the brake flexible hose bracket bolt and disconnect the bracket from the wheel knuckle. 7. Remove and discard the upper ball joint nut. 8. Remove and discard the shock absorber lower nut and bolt. 9. Using the Ball Joint Separator, disconnect the upper arm ball joint from the wheel knuckle and remove the shock absorber and spring assembly. 10. NOTE: If the individual spring and/or shock components are not being serviced, continue to the Installation procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension > Page 5603 NOTE: For reference during assembly, index-mark the upper mount, spring and shock absorber. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 11. NOTE: Use the hex-holding feature to prevent the shock rod from turning while removing the nut. While holding the shock rod, remove the nut and the shock absorber. - Discard the nut. 12. Remove the upper mount, dust boot and insulator. Installation NOTICE: Do not tighten the lower shock nut until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load and bushing damage may occur. 1. Position the shock absorber and spring and install the dust boot, insulator and the upper mount. 2. NOTE: Align the index marks made during disassembly. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. NOTE: Use the hex-holding feature to prevent the shock rod from turning while installing the nut. Using the hex-holding feature to hold the shock rod, install the shock absorber and the shock rod nut. - Tighten the new nut to 56 Nm (41 lb-ft). 4. Install the shock absorber and spring assembly and connect the upper arm ball joint to the wheel knuckle. - Tighten the new nut to 115 Nm (85 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension > Page 5604 5. NOTE: Do not tighten the nut at this time. Loosely install the new shock absorber lower nut and bolt. 6. Connect the brake flexible hose bracket to the wheel knuckle and install the bolt. - Tighten the bolt to 30 Nm (22 lb-ft). 7. Attach the flexible hose retainer to the speed sensor harness. 8. Install the tie-rod end nut. - Tighten to 150 Nm (111 lb-ft). 9. Install the wheel and tire. 10. Install the new shock absorber upper mount nuts. - Tighten to 40 Nm (30 lb-ft). 11. With the weight of the vehicle on the wheel and tire, tighten the shock absorber lower nut to 550 Nm (406 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension > Page 5605 Suspension Strut / Shock Absorber: Service and Repair Vehicle Dynamic Suspension Air Shock Absorber - Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension > Page 5606 Removal and Installation 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: Vent all air pressure from the air suspension system prior to disconnecting or removing any air suspension components. It is dangerous to remove air suspension components while under pressure. Failure to follow this instruction may result in serious personal injury. NOTICE: Vehicles built prior to 12/03/2007 use a longer air spring and shock absorber than vehicles built after 12/03/2007. To prevent component damage, it is important to use the correct air spring and or shock absorber when replacing these parts. NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be used if installation is necessary. Do not use a new 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. Using the scan tool, vent the appropriate air spring. 2. Remove the lower arm. 3. Disconnect the air spring solenoid valve electrical connector. 4. Disconnect the air line at the air valve. - Compress the orange quick connect lock ring, then pull downward on the air supply line. 5. Remove and discard the 3 shock upper nuts. - To install, tighten to 40 Nm (30 lb-ft). 6. Remove the air shock absorber. 7. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step 14. NOTE: Use the hex-holding feature to prevent the shock rod from turning while removing the nut. Remove and discard the shock rod nut. - To install, tighten to 45 Nm (33 lb-ft). 8. Remove the shock rod upper washer and O-ring seal. - Discard the O-ring seal washer. 9. NOTICE: If the retainer tabs are broken, a new air spring must be installed, or failure of the air spring may occur. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension > Page 5607 NOTE: Index-mark the air spring and shock absorber for reference during the installation procedure. Depress the retainer tabs and remove the air spring. 10. Remove the shock rod lower O-ring seal, washer and jounce bumper. - Discard the seal and washer. 11. Remove and discard the 2 air spring lower O-ring seals. 12. Remove the 2 upper mount screws and the upper mount. - Discard the screws. - To install, tighten the new screws to 4 Nm (35 lb-in). 13. Remove and discard the 2 air spring upper O-ring seals. 14. NOTICE: Use a suitable press to install the upper mount retainer pins. Do not use a hammer or damage may occur. NOTICE: When installing the upper and lower shock rod O-ring seals and washers, it is important to install the washers with the flat face side positioned against the O-ring seals. Damage to the O-ring seals will occur if the rounded face side of the washers is positioned against the O-ring seals. NOTE: Make sure that all seals are clean and free of debris. NOTE: Apply a thin coat of grease to the new O-ring seals. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Trailing Arm - Upper Trailing Arm: Service and Repair Trailing Arm - Upper Trailing Arm - Upper 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 correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the upper trailing arm-to-wheel knuckle bolt. 3. Remove and discard the upper trailing arm-to-frame bolt and flagnut. 4. NOTE: After removal of the upper trailing arm, inspect the knuckle bushing for excessive wear or damage and install new as necessary. For additional information, refer to Wheel Knuckle Bushing See: Rear Knuckle/Service and Repair/Wheel Knuckle Bushing. Remove the upper trailing arm. Installation 1. NOTE: Do not tighten the bolt at this time. Install the upper trailing arm and loosely install the new upper trailing arm-to-frame bolt and flagnut. 2. NOTE: Do not tighten the bolt at this time. Loosely install the new upper trailing arm-to-wheel knuckle bolt. 3. Install the wheel and tire. 4. Lower the vehicle so that the weight of the vehicle is resting on the wheel and tires. 5. Tighten the upper trailing arm-to-frame bolt and flagnut to 275 Nm (203 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Trailing Arm - Upper > Page 5612 6. Tighten the upper trailing arm-to-wheel knuckle bolt to 250 Nm (184 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Trailing Arm - Upper > Page 5613 Trailing Arm: Service and Repair Trailing Arm - Lower Trailing Arm - Lower 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 correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the 2 lower trailing arm-to-wheel knuckle bolts. 3. Remove and discard the lower trailing arm-to-frame bolt and flagnut. 4. Remove the lower trailing arm. Installation 1. NOTE: Do not tighten the bolt at this time. Install the lower trailing arm and loosely install the new lower trailing arm-to-frame bolt and flagnut. 2. NOTE: Do not tighten the bolt at this time. Loosely install the 2 new lower trailing arm-to-wheel knuckle bolts. 3. Install the wheel and tire. 4. Lower the vehicle so that the weight of the vehicle is resting on the wheel and tires. 5. Tighten the 2 lower trailing arm-to-wheel knuckle bolts to 103 Nm (76 lb-ft). 6. Tighten the lower trailing arm-to-frame bolt to 275 Nm (203 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 parts, 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. Disconnect the wheel speed sensor electrical connector. 2. Remove the wheel and tire. 3. Remove the wheel speed sensor harness bracket bolt and detach the harness from the retainers. - To install, tighten to 12 Nm (106 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5618 4. NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose may result. Remove the 2 bolts and position the caliper and anchor plate aside. - Support the caliper using mechanic's wire. - To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the 4 bolts and the wheel bearing and wheel hub. - Discard the bolts. - To install, tighten to 175 Nm (129 lb-ft). 7. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel speed sensor. - To install, tighten to 18 Nm (159 lb-in). 8. NOTICE: If the original wheel bearing and wheel hub is being installed, a new O-ring seal must be installed or damage to the wheel bearing may occur. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5619 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing and Wheel Hub Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital parts 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 installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5620 1. Remove the wheel and tire. 2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the halfshaft nut. 3. Using a suitable hub puller, 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 may result. Remove the bolts and position the caliper and anchor plate assembly aside. - Support the caliper and anchor plate assembly using mechanic's wire. 5. Remove the brake disc. 6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 7. Remove the 4 bolts, the wheel bearing and wheel hub, and the wheel speed sensor as an assembly. - Route the sensor wiring through the access hole in the brake disc shield. - Discard the bolts. 8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and wheel hub. Installation 1. If necessary, install the wheel speed sensor and bolt. - Tighten to 18 Nm (159 lb-in). 2. Position the wheel bearing and wheel hub, and the wheel speed sensor. Install the 4 new wheel bearing and wheel hub bolts. - Route the sensor wiring through the access hole in the brake disc shield. - Tighten to 175 Nm (129 lb-ft). 3. Attach the wheel speed sensor harness to the retainers and connect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 4. Install the brake disc. 5. Position the caliper and anchor plate assembly and install the bolts. - Tighten to 190 Nm (140 lb-ft). 6. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Install the new halfshaft nut. - Tighten to 300 Nm (221 lb-ft). 7. Install the wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Rear Suspension Wheel Bearing and Wheel Hub Install the new halfshaft nut, tighten to .................................................................................................................................................... 300 Nm (221 lb-ft) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations Wheel Hub Lock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 5628 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 5629 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Service and Repair Wheel Hub (Locking): Service and Repair Integrated Wheel End (IWE) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire. 3. Remove the dust cap. 4. Remove and discard the axle nut. 5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE). 6. Remove the 3 IWE-to-wheel knuckle retaining bolts. 7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle. - Discard the tie-rod nut. 8. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 9. Remove the front brake flexible hose bracket bolt and position the brake hose aside. 10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle. - Discard the upper ball joint nut. 11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing. 12. Remove the IWE from the halfshaft outboard end. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Service and Repair > Page 5633 1. Compress the IWE and install a vacuum cap on the vacuum port. 2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE on halfshaft outboard end or component damage may occur. Install the IWE onto the halfshaft outboard end. 3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing. 4. Connect the upper ball joint and install a new nut. - Tighten to 115 Nm (85 lb-ft). 5. Connect the tie rod and install a new nut. - Tighten to 115 Nm (85 lb-ft). 6. Position the front brake flexible hose bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the wheel speed sensor harness bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 8. Install the 3 IWE-to-wheel knuckle retaining bolts. - Tighten to 12 Nm (106 lb-in). 9. Remove the IWE vacuum cap and connect the vacuum tubes. 10. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle nut or component damage may occur. Install the new axle nut. - Tighten to 27 Nm (20 lb-ft). 11. Install the dust cap. 12. Install the front wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Jacking Points - Front WARNING: Shut off the electrical power to the air suspension system prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Failure to follow this instruction may result in serious personal injury. WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions 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: 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. The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel. Jacking Points - Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 5638 NOTICE: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire and wheel. Lifting Points - Front and Rear Locate the front hoist adapters and rear hoist adapters as indicated. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5644 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5645 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5648 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5649 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5650 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5651 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5657 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5658 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5661 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5662 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5663 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5664 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 Expedition 2wd Workshop Manual (V8-5.4L (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 parts, 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. Disconnect the wheel speed sensor electrical connector. 2. Remove the wheel and tire. 3. Remove the wheel speed sensor harness bracket bolt and detach the harness from the retainers. - To install, tighten to 12 Nm (106 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5669 4. NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose may result. Remove the 2 bolts and position the caliper and anchor plate aside. - Support the caliper using mechanic's wire. - To install, tighten to 200 Nm (148 lb-ft). 5. Remove the brake disc. 6. Remove the 4 bolts and the wheel bearing and wheel hub. - Discard the bolts. - To install, tighten to 175 Nm (129 lb-ft). 7. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel speed sensor. - To install, tighten to 18 Nm (159 lb-in). 8. NOTICE: If the original wheel bearing and wheel hub is being installed, a new O-ring seal must be installed or damage to the wheel bearing may occur. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5670 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing and Wheel Hub Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital parts 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 installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5671 1. Remove the wheel and tire. 2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the halfshaft nut. 3. Using a suitable hub puller, 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 may result. Remove the bolts and position the caliper and anchor plate assembly aside. - Support the caliper and anchor plate assembly using mechanic's wire. 5. Remove the brake disc. 6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 7. Remove the 4 bolts, the wheel bearing and wheel hub, and the wheel speed sensor as an assembly. - Route the sensor wiring through the access hole in the brake disc shield. - Discard the bolts. 8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and wheel hub. Installation 1. If necessary, install the wheel speed sensor and bolt. - Tighten to 18 Nm (159 lb-in). 2. Position the wheel bearing and wheel hub, and the wheel speed sensor. Install the 4 new wheel bearing and wheel hub bolts. - Route the sensor wiring through the access hole in the brake disc shield. - Tighten to 175 Nm (129 lb-ft). 3. Attach the wheel speed sensor harness to the retainers and connect the wheel speed sensor electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield. 4. Install the brake disc. 5. Position the caliper and anchor plate assembly and install the bolts. - Tighten to 190 Nm (140 lb-ft). 6. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Install the new halfshaft nut. - Tighten to 300 Nm (221 lb-ft). 7. Install the wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Rear Suspension Wheel Bearing and Wheel Hub Install the new halfshaft nut, tighten to .................................................................................................................................................... 300 Nm (221 lb-ft) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations Wheel Hub Lock Solenoid: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 5679 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 5680 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair Wheel Hub (Locking): Service and Repair Integrated Wheel End (IWE) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire. 3. Remove the dust cap. 4. Remove and discard the axle nut. 5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE). 6. Remove the 3 IWE-to-wheel knuckle retaining bolts. 7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle. - Discard the tie-rod nut. 8. Remove the wheel speed sensor harness bracket bolt and position the harness aside. 9. Remove the front brake flexible hose bracket bolt and position the brake hose aside. 10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle. - Discard the upper ball joint nut. 11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing. 12. Remove the IWE from the halfshaft outboard end. Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service and Repair > Page 5684 1. Compress the IWE and install a vacuum cap on the vacuum port. 2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE on halfshaft outboard end or component damage may occur. Install the IWE onto the halfshaft outboard end. 3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward. Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing. 4. Connect the upper ball joint and install a new nut. - Tighten to 115 Nm (85 lb-ft). 5. Connect the tie rod and install a new nut. - Tighten to 115 Nm (85 lb-ft). 6. Position the front brake flexible hose bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 7. Position the wheel speed sensor harness bracket and install the bolt. - Tighten to 12 Nm (106 lb-in). 8. Install the 3 IWE-to-wheel knuckle retaining bolts. - Tighten to 12 Nm (106 lb-in). 9. Remove the IWE vacuum cap and connect the vacuum tubes. 10. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle nut or component damage may occur. Install the new axle nut. - Tighten to 27 Nm (20 lb-ft). 11. Install the dust cap. 12. Install the front wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Tighten the wheel nuts in a star/cross pattern. Tighten to.................................................................... ...............................................................................................................................135 Nm (100 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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 parts, 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. NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the brake hose or damage to the hose may result. Remove the 2 bolts and position the brake caliper and anchor plate assembly aside. - Support the brake caliper and anchor plate assembly using mechanic's wire. 3. Remove the brake disc. 4. Using the C-Frame and Screw Assembly, remove the wheel stud. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5690 Installation 1. 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. Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by the original wheel stud. - Place 4 washers over the outside end of the wheel stud and thread a standard wheel nut onto the wheel stud with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the wheel hub flange. 2. Remove the wheel nut and washers. 3. Install the brake disc. 4. Position the brake caliper and anchor plate assembly and install the bolts. - Tighten the bolts to 200 Nm (148 lb-ft). 5. Install the wheel and tire. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5691 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 correct retention of these parts. 1. 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. 2. NOTICE: Never use a hammer to remove a wheel stud. Damage to the wheel hub may result. Place the wheel hub in a soft-jawed vise and, using the C-Frame and Screw, remove the wheel stud. Installation 1. Position the new wheel stud in the wheel bearing and hub assembly, aligning the serrations in the wheel hub flange made by the original wheel stud. 2. NOTICE: Do not use power tools to install the wheel stud. The serrations on the flange 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 4 washers and a wheel nut on the wheel stud and tighten the wheel nut until the stud seats against the flange. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5692 3. Remove the wheel nut and washers. - Discard the wheel nut. 4. Install the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Rear Suspension. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 10-5-5 > Mar > 10 > A/C Blend Door Actuator Clicking Noises Air Door Actuator / Motor: Customer Interest A/C - Blend Door Actuator Clicking Noises TSB 10-5-5 03/29/10 TEMPERATURE BLEND DOOR ACTUATOR NOISE FORD: 2009-2010 Expedition LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles may exhibit a noise coming from the dash area after vehicle is started or when the customer requests a Heating Ventilation Air Conditioning (HVAC) temperature change. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE Test both driver and passenger side temperature blend door actuators on dual zone HVAC systems. 1. Start the vehicle and set the heater control to full heat. Repeat for full cool setting. a. If a clicking noise is not heard at either end of the travel, do not continue with this procedure. b. If a clicking noise is heard at either end of the travel, proceed to Step 2. 2. Replace the temperature blend door actuator with revise parts. Refer to the Workshop Manual, Section 412-01. NOTE THE IGNITION KEY MUST BE OFF WHEN REPLACING THE ACTUATOR. ENERGIZING THE ACTUATOR BEFORE INSTALLATION ON THE HVAC CASE WILL CAUSE THE PART TO BECOME MISS POSITIONED AND CORRECT ORIENTATION WILL BE LOST. INCORRECT ACTUATOR OPERATION MAY RESULT. 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 100505A 2009-2010 Expedition: 0.5 Hr. Replace The Right Blend Door Actuator, Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 100505A 2009-2010 Navigator: 0.7 Hr. Replace The Right Blend Door Actuator, Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 10-5-5 > Mar > 10 > A/C Blend Door Actuator Clicking Noises > Page 5703 100505B 2009-2010 Expedition, 4.3 Hrs. Navigator: Replace The Left Blend Door Actuator, Includes Time To Remove And Install The Instrument Panel (Do Not Use With Any Other Labor Operations) 100505C 2009-2010 Expedition, 4.4 Hrs. Navigator: Replace Both Left And Right Blend Door Actuators, Includes Time To Remove And Install The Instrument Panel (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19E616 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 10-5-5 > Mar > 10 > A/C - Blend Door Actuator Clicking Noises Air Door Actuator / Motor: All Technical Service Bulletins A/C - Blend Door Actuator Clicking Noises TSB 10-5-5 03/29/10 TEMPERATURE BLEND DOOR ACTUATOR NOISE FORD: 2009-2010 Expedition LINCOLN: 2009-2010 Navigator ISSUE Some 2009-2010 Expedition and Navigator vehicles may exhibit a noise coming from the dash area after vehicle is started or when the customer requests a Heating Ventilation Air Conditioning (HVAC) temperature change. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE Test both driver and passenger side temperature blend door actuators on dual zone HVAC systems. 1. Start the vehicle and set the heater control to full heat. Repeat for full cool setting. a. If a clicking noise is not heard at either end of the travel, do not continue with this procedure. b. If a clicking noise is heard at either end of the travel, proceed to Step 2. 2. Replace the temperature blend door actuator with revise parts. Refer to the Workshop Manual, Section 412-01. NOTE THE IGNITION KEY MUST BE OFF WHEN REPLACING THE ACTUATOR. ENERGIZING THE ACTUATOR BEFORE INSTALLATION ON THE HVAC CASE WILL CAUSE THE PART TO BECOME MISS POSITIONED AND CORRECT ORIENTATION WILL BE LOST. INCORRECT ACTUATOR OPERATION MAY RESULT. 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 100505A 2009-2010 Expedition: 0.5 Hr. Replace The Right Blend Door Actuator, Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) 100505A 2009-2010 Navigator: 0.7 Hr. Replace The Right Blend Door Actuator, Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 10-5-5 > Mar > 10 > A/C - Blend Door Actuator Clicking Noises > Page 5709 100505B 2009-2010 Expedition, 4.3 Hrs. Navigator: Replace The Left Blend Door Actuator, Includes Time To Remove And Install The Instrument Panel (Do Not Use With Any Other Labor Operations) 100505C 2009-2010 Expedition, 4.4 Hrs. Navigator: Replace Both Left And Right Blend Door Actuators, Includes Time To Remove And Install The Instrument Panel (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19E616 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator Air Door Actuator / Motor: Locations Defrost/Panel/Floor Mode Door Actuator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5712 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5713 Air Door Actuator / Motor: Locations Air Inlet Mode Door Actuator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5714 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5715 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5716 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5717 Air Door Actuator / Motor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5718 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5719 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5720 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5721 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5722 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5723 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5724 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5725 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5726 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defrost/Panel/Floor Mode Door Actuator > Page 5727 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5730 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5731 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5732 Air Door Actuator / Motor: Diagrams Auxiliary Temperature Blend Door Actuator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5733 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5734 Air Door Actuator / Motor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5735 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5736 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5737 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5738 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5739 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5740 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5741 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Defrost/Panel/Floor Mode Door Actuator > Page 5742 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Defrost/Panel/Floor Door Mode Door Actuator - Defrost/Panel/Floor Door Removal and Installation NOTE: The defrost/panel/floor mode door actuator can be accessed from underneath the LH side of the instrument panel. 1. Disconnect the defrost/panel/floor door mode door actuator electrical connector. 2. Remove the 2 defrost/panel/floor door mode door actuator screws. 3. Remove the defrost/panel/floor door mode door actuator. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5745 Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Air Inlet Door Mode Door Actuator - Air Inlet Door Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Remove the junction box cover at the RH lower A-pillar. 3. Remove the 3 air inlet mode door actuator screws. 4. Disconnect the air inlet mode door actuator electrical connector. 5. Remove the air inlet mode door actuator. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5746 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - RH Temperature Blend Door Actuator - RH Removal and Installation 1. Remove the Audio Control Module (ACM). 2. Disconnect the RH temperature blend door actuator electrical connector. 3. Remove the 2 RH temperature blend door actuator screws. 4. Remove the RH temperature blend door actuator. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5747 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - LH Temperature Blend Door Actuator - LH Removal and Installation 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 4 floor duct screws. 3. Remove the floor duct. 4. Disconnect the LH temperature blend door actuator electrical connector. 5. Remove the 2 LH temperature blend door actuator screws. 6. Remove the LH temperature blend door actuator. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5748 Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Defrost/Panel/Floor Door Mode Door Actuator - Defrost/Panel/Floor Door Removal and Installation NOTE: The defrost/panel/floor mode door actuator can be accessed from underneath the LH side of the instrument panel. 1. Disconnect the defrost/panel/floor door mode door actuator electrical connector. 2. Remove the 2 defrost/panel/floor door mode door actuator screws. 3. Remove the defrost/panel/floor door mode door actuator. 4. To install, reverse the removal procedure. Mode Door Actuator - Air Inlet Door Mode Door Actuator - Air Inlet Door Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5749 Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Remove the junction box cover at the RH lower A-pillar. 3. Remove the 3 air inlet mode door actuator screws. 4. Disconnect the air inlet mode door actuator electrical connector. 5. Remove the air inlet mode door actuator. 6. To install, reverse the removal procedure. Temperature Blend Door Actuator - RH Temperature Blend Door Actuator - RH Removal and Installation 1. Remove the Audio Control Module (ACM). 2. Disconnect the RH temperature blend door actuator electrical connector. 3. Remove the 2 RH temperature blend door actuator screws. 4. Remove the RH temperature blend door actuator. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5750 Temperature Blend Door Actuator - LH Temperature Blend Door Actuator - LH Removal and Installation 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 4 floor duct screws. 3. Remove the floor duct. 4. Disconnect the LH temperature blend door actuator electrical connector. 5. Remove the 2 LH temperature blend door actuator screws. 6. Remove the LH temperature blend door actuator. 7. To install, reverse the removal procedure. Auxiliary Mode Door Actuator Auxiliary Mode Door Actuator - Expedition, Navigator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5751 Removal and Installation 1. Remove the RH quarter trim panel cup holder. 2. Remove the RH quarter trim panel utility tray. 3. Remove the 3 auxiliary mode door actuator screws. 4. Disconnect the auxiliary mode door actuator electrical connector. 5. Remove the auxiliary mode door actuator. 6. To install, reverse the removal procedure. Auxiliary Mode Door Actuator - Expedition EL, Navigator L Auxiliary Mode Door Actuator - Expedition EL, Navigator L Removal and Installation 1. Fold the third row seats fully forward. 2. Remove the RH D-pillar trim panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5752 3. Remove the liftgate sill plate. 4. Remove the rear floor cargo space trim panel. 5. Position the rear floor cargo space floor trim aside and remove the RH rear quarter trim panel bolt. 6. Remove the RH quarter trim panel utility tray. 7. Detach the 3 rear and 5 upper RH quarter trim panel clips and position the quarter trim panel aside. 8. Disconnect the auxiliary mode door actuator electrical connector. 9. Remove the 2 auxiliary mode door actuator screws. 10. Remove the auxiliary mode door actuator. 11. To install, reverse the removal procedure. Auxiliary Temperature Blend Door Actuator Auxiliary Temperature Blend Door Actuator - Expedition, Navigator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5753 Removal and Installation 1. Remove the RH quarter trim panel. 2. Disconnect the auxiliary temperature blend door actuator electrical connector. 3. Remove the 4 auxiliary temperature blend door actuator screws. 4. Remove the auxiliary temperature blend door actuator. 5. To install, reverse the removal procedure. Auxiliary Temperature Blend Door Actuator - Expedition EL, Navigator L Auxiliary Temperature Blend Door Actuator - Expedition EL, Navigator L Removal and Installation 1. Fold the third row seats fully forward. 2. Remove the RH D-pillar trim panel. 3. Remove the liftgate sill plate. 4. Remove the rear floor cargo space trim panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator - Defrost/Panel/Floor Door > Page 5754 5. Position the rear floor cargo space floor trim aside and remove the RH rear quarter trim panel bolt. 6. Remove the RH quarter trim panel utility tray. 7. Detach the 3 rear and 5 upper RH quarter trim panel clips and position the quarter trim panel aside. 8. Disconnect the auxiliary temperature blend door actuator electrical connector. 9. Remove the 2 auxiliary temperature blend door actuator screws. 10. Remove the auxiliary temperature blend door actuator. 11. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct Air Duct: Service and Repair Floor Duct Floor Duct Removal and Installation 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 4 floor duct screws. 3. Remove the floor duct. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 5759 Air Duct: Service and Repair Footwell Duct - Rear Footwell Duct - Rear Removal and Installation All vehicles 1. Remove the front seats. 2. Remove the front floor console. 3. Remove the RH and LH lower cowl trim panels and front door sill plates. Navigator only 4. Remove the upper and lower instrument panel bracket bolts and position the instrument panel bracket aside. - To install, tighten to 9 Nm (80 lb-in). All vehicles 5. Fold back the carpet to completely uncover the rear footwell duct. 6. Remove the 2 rear footwell duct pin-type retainers. 7. Remove the rear footwell duct. 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Register - Climate Control Air Register: Service and Repair Register - Climate Control Register - Expedition Removal and Installation LH register 1. Remove the steering column opening cover. 2. Remove the 4 steering column opening reinforcement bolts and the steering column reinforcement. 3. Remove the LH outer instrument panel trim panel. RH register 4. Lower the glove compartment. LH or RH register 5. Working through the instrument panel opening, depress the 2 clips on the sides of the register barrel and tilt the bottom of the register outward to keep the clips from re-engaging. 6. NOTE: RH register shown, LH register similar. Using 2 suitable tools, release the clips through the demister nozzle opening and remove the register. Center registers 7. Remove the center instrument panel finish panel. 8. Working through the opening below the Audio Control Module (ACM), release the 3 register retaining clips and remove the register. All registers 9. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Register - Climate Control > Page 5764 Air Register: Service and Repair Register - Auxiliary Climate Control Register Removal and Installation 1. Fabricate a removal tool from a 3.175 mm (0.12 in) diameter rod. 2. Rotate the register with the removal tool to align the retaining ears with the clearance openings and remove the register. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5768 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5769 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations Auxiliary Blower Motor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations > Page 5774 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations > Page 5775 Auxiliary Blower Motor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 5780 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 5781 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 5782 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5785 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5786 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5787 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5788 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5789 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5790 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5791 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Blower Motor Resistor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Blower Motor Resistor > Page 5796 Blower Motor Resistor: Locations Auxiliary Blower Motor Resistor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Blower Motor Resistor > Page 5797 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor > Page 5800 Blower Motor Resistor: Diagrams Auxiliary Blower Motor Resistor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor > Page 5801 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Resistor - Blower Motor Blower Motor Resistor: Testing and Inspection Resistor - Blower Motor Climate Control System Component Tests Resistor - Blower Motor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Resistor - Blower Motor > Page 5804 Blower Motor Resistor: Testing and Inspection Resistor - Auxiliary Blower Motor Climate Control System Component Tests Resistor - Auxiliary Blower Motor (Expedition/Navigator) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Resistor - Blower Motor > Page 5805 Blower Motor Resistor: Testing and Inspection Resistor - Auxiliary Blower Motor (Expedition EL/Navigator L) Climate Control System Component Tests Resistor - Auxiliary Blower Motor (Expedition EL/Navigator L) Ford Expedition 2wd Workshop Manual (V8-5.4L (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. Disconnect the blower motor resistor electrical connector. 2. Remove the 2 blower motor resistor screws. 3. Remove the blower motor resistor. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor > Page 5808 Blower Motor Resistor: Service and Repair Auxiliary Blower Motor Resistor Auxiliary Blower Motor Resistor Removal and Installation NOTE: Expedition or Navigator shown, Expedition EL or Navigator L similar. All vehicles 1. Remove the RH quarter trim panel access panel. Expedition or Navigator only 2. Remove the blower motor resistor. - Disconnect the blower motor resistor electrical connector. - Remove the 2 blower motor resistor screws and the blower motor resistor. Expedition EL or Navigator L only 3. Remove the blower motor resistor. - Disconnect the blower motor resistor electrical connector. - Remove the blower motor resistor screw. - Detach the 2 blower motor resistor clips and remove the blower motor resistor. All vehicles 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5812 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5813 Blower Motor Switch: Service and Repair Blower Motor Speed Control Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 5820 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 5821 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the upper radiator sight shield. 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor > Page 5824 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor In-Vehicle Temperature Sensor - Expedition 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air gap clearance.................................................................................................................................. ...................................0.35-0.65 mm (0.014-0.026 in) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5829 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5833 Compressor Clutch Coil: Service and Repair Clutch and Clutch Field Coil Removal 1. Remove the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor See: Service and Repair. 2. Remove the A/C clutch disc and hub bolt. 1. Using the Compressor Clutch Holding Tool, hold the A/C clutch disc and hub. 2. Remove the A/C clutch disc and hub bolt. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5834 3. Remove the A/C clutch disc and hub. 4. Remove the A/C compressor pulley snap ring. 5. NOTICE: Do not use air tools. Damage to the Air Conditioning (A/C) clutch pulley or A/C compressor may result. Using the Compressor Pulley Remover, remove the A/C compressor pulley. 1. Install the Compressor Pulley Remover. 2. Remove the A/C compressor pulley. 6. Remove the A/C clutch field coil snap ring. 7. Remove the A/C clutch field coil electrical connector screw. 8. Remove the A/C clutch field coil. Installation NOTE: A new A/C compressor may come equipped with a clutch and pulley. If not, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found on the friction surface, a new A/C clutch disc and hub and a new A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. 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. 3. Install the A/C clutch field coil. 4. Install the A/C clutch field coil electrical connector screw. 5. Install the A/C clutch field coil snap ring. 6. NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation. Install the A/C compressor pulley. 7. Install the A/C compressor pulley snap ring with the bevel side out. 8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 9. Install the A/C clutch disc and hub. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5835 10. Using the Compressor Clutch Holding Tool, install the A/C compressor clutch disc and hub bolt. 1. Hold the A/C clutch disc and hub with the Compressor Clutch Holding Tool. 2. Tighten the bolt to 14 Nm (124 lb-in). 11. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers. 12. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5839 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation Air Conditioning A/C Condenser/Power Steering Combo Cooler The A/C condenser/power steering combo cooler 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. The receiver/drier is incorporated onto the LH side of the condenser core. The receiver/drier cartridge is a separate component and can be removed and installed separately from the condenser core. The top portion of the condenser/power steering combo cooler is partitioned from the refrigerant system and is used for power steering fluid cooling. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5843 Condenser HVAC: Service and Repair Condenser Core Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Disconnect the battery cables. 4. Remove the upper radiator sight shield. 5. Remove the RH and LH headlamp assemblies. 6. Remove the air cleaner outlet tube. 7. Remove the 4 junction box bolts and position the junction box aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5844 8. Detach the power steering cooler line clip. 9. Remove the condenser inlet fitting bolt and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 10. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). 11. NOTE: RH bolts shown, LH similar. Remove the 2 cooling module and 2 cooling fan shroud bolts. 12. Release the clamps and disconnect the 2 power steering cooler lines from the condenser core. 13. Remove the 3 pin-type retainers and detach the LH air deflector from the condenser bracket. 14. Remove the 2 RH outer air deflector pin-type retainers and position the air deflector aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5845 15. Remove the 2 pin-type retainers and detach the RH air deflector from the condenser bracket. 16. Remove the 9 lower radiator splash shield pin-type retainers and position the shield aside. 17. Release the clamps and disconnect the 2 transmission cooler lines from the transmission cooler. 18. Detach the transmission cooler line pin-type retainer from the condenser core bracket. 19. NOTE: The cooling module must be positioned rearward to raise and detach the 4 condenser mounts from the cooling module. NOTE: The condenser must be removed from below the vehicle. Detach and remove the condenser core and transmission cooler as an assembly in the following sequence. 1. Position the cooling module rearward enough to allow the condenser to be lifted upward. 2. Depress the retaining tabs on the 2 lower condenser mounting brackets and detach the 4 condenser mounting brackets from the cooling module. 3. Position the top of the condenser forward to detach the top lip of the condenser bracket from the cooling module and remove the condenser core and bracket. 20. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 21. Fill the power steering fluid level. 22. Fill the transmission fluid level. 23. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Assembly Control Assembly: Service and Repair Auxiliary Climate Control Assembly Auxiliary Climate Control Assembly Removal and Installation 1. Remove the floor console upper finish panel. 2. Remove the 2 floor console rear finish panel screws. 3. Disengage the 6 clips and remove the floor console rear finish panel. - Disconnect the 3 floor console harness electrical connectors. 4. Remove the 4 auxiliary climate control assembly screws. 5. Remove the auxiliary climate control assembly. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Assembly > Page 5851 Control Assembly: Service and Repair Heating Ventilation Air Conditioning (HVAC) Module Heating Ventilation Air Conditioning (HVAC) Module Removal and Installation NOTE: Navigator shown, Expedition similar. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC > Page 5856 Control Module HVAC: Locations HVAC Module, DATC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC > Page 5857 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC Control Module HVAC: Diagrams HVAC Module, DATC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 5860 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 5861 Control Module HVAC: Diagrams HVAC Module, EMTC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 5862 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 5863 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 liquid refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube, continues over to the plate/fin sections and then moves out of the evaporator core through the evaporator core outlet tube as a vapor. Airflow from the blower motor is cooled and dehumidified as it flows through the evaporator core fins. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 5867 Evaporator Core: Testing and Inspection Climate Control System Component Tests Evaporator/Condenser Core - On-Vehicle Leak Test 1. Discharge and recover the refrigerant. 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. Disconnect the suspect evaporator core or condenser core from the A/C system. 3. Clean the manifold fittings. 4. Connect the appropriate test fittings to the condenser or evaporator core tube connections. 5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter that will activate the valve. The test is not valid if the shut-off valve does not open. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core or condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low-pressure gauge indicates 101 kPa (30 in-Hg). The 45-minute evacuation is necessary to remove any refrigerant from oil left in the evaporator core or condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low-pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low-pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new evaporator core or condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low-pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low-pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the evaporator core or condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss. 9. If the evaporator core or condenser core does leak, as verified by the above procedure, install a new evaporator core or condenser core. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Evaporator Core: Service and Repair Evaporator Core 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. NOTE: Installation of a new receiver/drier cartridge 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 receiver/drier cartridge. NOTE: A new evaporator core seal is supplied as a kit with the evaporator core service part. Failure to install this seal, or failure to install it correctly, will result in air bypassing the evaporator core and loss of cooling efficiency. 1. Remove the plenum chamber. For additional information, refer to Plenum Chamber See: Housing Assembly HVAC/Service and Repair/Plenum Chamber. 2. Remove 2 heater core quick disconnect fitting clips and the dash panel seal. 3. Detach the wire harness from the upper half of the heater core and evaporator core housing. 4. Remove the 6 air inlet duct screws and the air inlet duct. 5. Remove the 15 heater core and evaporator core housing screws. 6. Separate the 2 halves of the heater core and evaporator core housing. 7. Remove the evaporator core. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 5870 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 5871 Evaporator Core: Service and Repair Auxiliary Evaporator Core Auxiliary Evaporator Core Removal and Installation NOTE: The auxiliary evaporator core is not available as a separate component for Expedition EL or Navigator L vehicles and is serviced only as an assembly with the auxiliary heater core and evaporator core housing. The auxiliary evaporator core is serviced as an individual component for Expedition and Navigator vehicles. NOTE: If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. All vehicles 1. Remove the auxiliary heater core and evaporator core housing. For additional information, refer to Auxiliary Heater Core and Evaporator Core Housing - Expedition, Navigator See: Housing Assembly HVAC/Service and Repair/Auxiliary Heater Core and Evaporator Core Housing or Auxiliary Heater Core - Expedition EL, Navigator L See: Heater Core/Service and Repair/Auxiliary Heater Core - Expedition EL, Navigator L. Expedition EL or Navigator L 2. Transfer the components from the old heater core and evaporator core housing to the new heater core and evaporator core housing as needed. 3. Install the auxiliary heater core and evaporator core housing. For additional information, refer to Auxiliary Heater Core - Expedition EL, Navigator L See: Heater Core/Service and Repair/Auxiliary Heater Core - Expedition EL, Navigator L. Expedition or Navigator only 4. Remove the Thermostatic Expansion Valve (TXV) fitting bolt and disconnect the fitting. - Discard the O-ring seals. 5. Remove the 12 evaporator/heater core access cover screws. 6. Remove the evaporator/heater core access cover. - Disconnect the evaporator drain tube. 7. Remove the evaporator core. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 5872 8. To install, reverse the removal procedure. - Install new O-ring seals. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5876 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5877 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Air Conditioning Evaporator Temperature Sensor The evaporator temperature sensor communicates the evaporator fin temperature to the HVAC module. The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the A/C compressor clutch when the evaporator temperature sensor reading falls below acceptable levels, and by engaging the A/C compressor clutch when the discharge air temperature rises above acceptable levels. The evaporator temperature sensor electrical connector is located outside of the heater core and evaporator core housing behind the glove compartment, with the sensor pigtail leading into the housing to the sensor probe which is inserted between the evaporator core fins. The evaporator temperature sensor is not available as a separate component. To install a new evaporator temperature sensor, a new heater core and evaporator core housing must be installed. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning > Page 5880 Evaporator Temperature Sensor / Switch: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 5881 Evaporator Temperature Sensor / Switch: Service and Repair Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor Removal and Installation 1. Detach the glove compartment dampener and lower the glove compartment. 2. Disconnect the evaporator discharge air temperature sensor electrical connector. 3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Thermostatic Expansion Valve (TXV) Expansion Block/Orifice Tube: Description and Operation Thermostatic Expansion Valve (TXV) Air Conditioning Thermostatic Expansion Valve (TXV) The TXV is located between the evaporator core lines and the TXV manifold and tube assembly at the RH rear of the engine compartment. The TXV 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. Refrigerant entering and exiting the evaporator core passes through the TXV through 2 separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Thermostatic Expansion Valve (TXV) > Page 5886 Expansion Block/Orifice Tube: Description and Operation A/C Pressure Transducer Air Conditioning A/C Pressure Transducer The A/C pressure transducer communicates the compressor discharge pressure to the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates excessively high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Thermostatic Expansion Valve - Climate Control Expansion Block/Orifice Tube: Service and Repair Thermostatic Expansion Valve - Climate Control Thermostatic Expansion Valve Removal and Installation 1. Recover the refrigerant. 2. Remove the Thermostatic Expansion Valve (TXV) manifold and tube bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 3. Detach the wire harness pin-type retainer and position the harness aside. 4. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Thermostatic Expansion Valve - Climate Control > Page 5889 - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 5. Remove the TXV fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the 2 TXV bolts. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the TXV. - Discard the gasket seals. 8. To install, reverse the removal procedure. - Install a new O-ring seal and new gasket seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 9. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Thermostatic Expansion Valve - Climate Control > Page 5890 Expansion Block/Orifice Tube: Service and Repair Thermostatic Expansion Valve - Auxiliary Climate Control Thermostatic Expansion Valve - Expedition, Navigator Removal and Installation 1. Recover the refrigerant. 2. Remove the RH quarter trim panel. 3. Remove the Thermostatic Expansion Valve (TXV) fitting bolt and disconnect the fitting. - Discard the O-ring seals. 4. Remove the 2 TXV bolts. 5. Remove the TXV. - Discard the O-ring seals. 6. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 7. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Thermostatic Expansion Valve - Climate Control > Page 5891 Expansion Block/Orifice Tube: Service and Repair Thermostatic Expansion Valve - Expedition EL, Navigator L Thermostatic Expansion Valve - Expedition EL, Navigator L Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the auxiliary evaporator outlet and inlet line rear fitting nut. - Discard the gasket seals. - To install, tighten to 12 Nm (106 lb-in). 4. Remove the 2 Thermostatic Expansion Valve (TXV) bolts and the TXV. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. - Install new O-ring seals and gasket seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 6. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 following 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: Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in the heater 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-specified clamps can cause leakage at the heater hose connection and damage the heater core. Check the integrity of the heater hose clamps. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5896 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 hoses to see if they are hot. 4. If the outlet only is not hot: - the heater core may have an air pocket. - the heater core may be plugged. 5. If the inlet only is not hot: - the thermostat may not be working correctly. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5897 Heater Core: Testing and Inspection Heater Core - Pressure Test Climate Control System Component Tests Heater Core - Pressure Test WARNING: Before disconnecting any heater water hoses, shut OFF the engine and wait until engine is fully cool. Failure to comply with this warning may result in serious injury or burns from hot liquid escaping from the engine cooling system. Use the Pressure Test Kit to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Drain the coolant from the cooling system. 2. Disconnect the heater 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 hoses with water and install the plug BT-7422-B and the adapter BT-7422-A from the Pressure Test Kit. Secure the heater 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 hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle and carry out the bench test. See: Heater Core - Bench Test Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5898 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 hoses with plug and adapter to the core tubes. Then connect 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, install a new heater core. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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 8 plenum chamber screws. 3. Release the plenum chamber clip and position the plenum chamber aside. 4. Remove 2 heater core fitting clips and the dash panel seal. 5. Remove the heater core tube bracket screw and the heater core tube bracket. 6. Remove the heater core bracket screw and the heater core bracket. 7. Remove the heater core. 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 5901 Heater Core: Service and Repair Auxiliary Heater Core Auxiliary Heater Core - Expedition, Navigator 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 auxiliary heater core and evaporator core housing. For additional information, refer to Auxiliary Heater Core and Evaporator Core Housing - Expedition, Navigator See: Housing Assembly HVAC/Service and Repair/Auxiliary Heater Core and Evaporator Core Housing. 2. Release the clip and open the floorpan bracket. 3. Remove the heater core tube bracket screw and the heater core tube bracket. 4. Remove the 12 evaporator/heater core access cover screws. 5. Remove the evaporator/heater core access cover. 6. Remove the heater core. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 5902 Heater Core: Service and Repair Auxiliary Heater Core - Expedition EL, Navigator L Auxiliary Heater Core - Expedition EL, Navigator L 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. NOTE: It is not necessary to install the new heater core tubes contained in the heater core service kit unless there is evidence of damage to the heater core tubes. New O-ring seals must be installed any time the heater core tubes are detached from the heater core. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the RH quarter trim panel. 4. Position a suitable drain pan and disconnect the 2 auxiliary heater outlet and inlet line quick disconnect fittings at the floorpan connections to allow any residual coolant to drain from the auxiliary heater core. 5. Remove the heater core door screw. 6. Remove the 2 auxiliary heater core tube fitting clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 5903 7. Disconnect the 2 auxiliary heater core tubes. 1. Position the auxiliary heater core partially out of the housing. 2. Disconnect the auxiliary heater core inlet tube. 3. Disconnect the auxiliary heater core outlet tube. - Discard the O-ring seals. 8. Remove the auxiliary heater core. 9. NOTE: Use only the O-ring seals contained in the auxiliary heater core service kit. NOTE: Verify that the heater core tube fittings are completely seated in the heater core before installing the heater core tube fitting clips. To install, reverse the removal procedure. 10. Fill the engine cooling system. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 pressure relief valve is incorporated in the A/C compressor to prevent damage to the A/C compressor and other system components by relieving unusually high system discharge pressure buildups. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Page 5907 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line Auxiliary Evaporator Outlet and Inlet Line Removal Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5912 NOTE: The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly for Expedition or Navigator vehicles. The auxiliary evaporator inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. NOTE: The auxiliary evaporator inlet and outlet lines for Expedition EL or Navigator L vehicles are installed from the factory as a single one-piece assembly including both lines. The replacement part is supplied as a multiple-piece kit for ease of installation. NOTE: For Expedition or Navigator vehicles, the following procedure can be used to remove and install one or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. For Expedition EL or Navigator L vehicles, both lines must be removed. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. NOTE: If only one auxiliary evaporator line is to be removed, disconnect only the desired line. Remove the auxiliary evaporator outlet and inlet line front fitting nut(s) and disconnect the fitting(s). - Discard the O-ring seals and gasket seals. 4. Remove the spare tire. 5. Remove the RH front wheel and tire. 6. Remove the RH fender splash shield. 7. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. 8. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition or Navigator only 9. NOTE: Both A/C fittings must be disconnected even if only one line is to be removed. Disconnect the auxiliary evaporator outlet and inlet line rear fittings. - Discard the O-ring seals. Expedition EL or Navigator L only 10. Remove the RH rear wheel and tire assembly. 11. Remove the auxiliary evaporator outlet and inlet line rear fitting nut and disconnect the fitting. - Discard the gasket seals. All vehicles 12. Remove the muffler. 13. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 14. Remove the 3 muffler heat shield bolts and the heat shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5913 15. Remove the 2 exhaust hanger bolts and the exhaust hanger. 16. Remove the RH Catalyst Monitor Sensor (CMS). 17. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 18. Remove the 3 remaining auxiliary line bracket nuts and the auxiliary line brackets. 19. NOTE: If installing only one auxiliary evaporator line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary evaporator line(s) in the same position as the fittings on the new line(s). Expedition EL or Navigator L only 20. Remove the center section(s) of the auxiliary evaporator line(s) through the RH rear wheel well opening between the body and the frame. Expedition or Navigator only 21. Remove the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the front of the vehicle between the RH catalytic converter and frame. All vehicles 22. Remove the remaining auxiliary evaporator inlet and outlet line pieces. Installation Expedition or Navigator only 1. Install the rear portion of the auxiliary evaporator line(s) and connect the auxiliary evaporator outlet and inlet line rear fittings. - Install new O-ring seals. Expedition EL or Navigator L only 2. Install the rear portion of the auxiliary evaporator outlet and inlet line. 3. Connect the auxiliary evaporator outlet and inlet line rear fitting and install the nut. - Install new gasket seals. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5914 - Tighten to 12 Nm (106 lb-in). All vehicles 4. Install the front portion of the auxiliary evaporator outlet and inlet line(s). 5. Connect the evaporator outlet and inlet line front fitting(s) and install the nut(s). - Install new O-ring seals and gasket seals. - Tighten to 15 Nm (133 lb-in). Expedition EL or Navigator L only 6. NOTE: Loosely connect, but do not tighten, the fittings. Install the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the front of the vehicle through RH rear wheel well opening between the body and the frame. Expedition or Navigator only 7. NOTE: Loosely connect, but do not tighten, the fittings. Install the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the rear of the vehicle through the opening between the RH catalytic converter and frame. All vehicles 8. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). 9. NOTE: Expedition/Navigator shown, Expedition EL or Navigator L similar. Tighten the middle auxiliary evaporator line fittings. 10. Inspect the auxiliary evaporator lines for correct installation. Loosen, reposition and tighten as needed. 11. Install the RH catalytic converter heat shield and the 3 rear catalytic converter heat shield bolts. 12. Install the exhaust hanger and the 2 exhaust hanger bolts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5915 13. Install the muffler heat shield and the 3 muffler heat shield bolts. 14. Install the RH CMS. 15. Install the muffler. 16. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 17. Install the front auxiliary line bracket and the front auxiliary line bracket nut. - Tighten to 5 Nm (44 lb-in). 18. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 19. Install the RH front fender splash shield. 20. Install the RH front wheel. Expedition EL or Navigator L only 21. Install the RH rear wheel and tire assembly. All vehicles 22. Install the spare tire. 23. Lubricate the refrigerant system with the correct amount of clean PAG oil. 24. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5916 Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line Compressor to Condenser Discharge Line Removal and Installation 1. Recover the refrigerant. 2. 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). 3. Remove the condenser inlet jumper line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Remove the compressor-to-condenser discharge line. 5. If removing the condenser inlet jumper line, remove the RH headlamp assembly. 6. If removing the condenser inlet jumper line, disconnect the A/C pressure transducer electrical connector. 7. If removing the condenser inlet jumper line, remove the condenser inlet fitting bolt and disconnect the fitting. - Discard the O-ring and gasket seals. - To install, tighten to 15 Nm (133 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5917 8. Remove the condenser inlet jumper line. 9. To install, reverse the removal procedure. - Install new gasket seals and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5918 Hose/Line HVAC: Service and Repair Thermostatic Expansion Valve Manifold and Tube Assembly Thermostatic Expansion Valve Manifold and Tube Assembly Removal and Installation 1. Recover the refrigerant. 2. Remove the RH headlamp assembly. 3. Remove the condenser outlet 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 3 PCM electrical connectors. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5919 5. Disconnect the 2 wire harness electrical connectors at the RH inner fender splash shield. 6. Remove the Thermostatic Expansion Valve (TXV) manifold and tube assembly bracket bolt. 7. Remove the TXV manifold and tube suction fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 8. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 9. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 10. Remove the TXV fitting nut and disconnect the fitting. - Discard the gasket seals. - To install, tighten to 15 Nm (133 lb-in). 11. Remove the TXV manifold and tube assembly. 12. To install, reverse the removal procedure. - Install new gasket seals and 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5920 Hose/Line HVAC: Service and Repair Auxiliary Heater Outlet and Inlet Line Auxiliary Heater Outlet and Inlet Line Removal NOTE: The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation. NOTE: The following procedure can be used to remove and install one or both the auxiliary heater inlet and auxiliary heater outlet lines. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5921 All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the spare tire. 4. Remove the RH front wheel and tire. 5. Remove the RH fender splash shield. 6. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and/or inlet line front quick disconnect fitting(s). 7. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket. 8. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt. Expedition EL or Navigator L only 9. Remove the RH rear wheel and tire assembly. All vehicles 10. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line. Disconnect the auxiliary heater outlet and inlet line rear quick disconnect fitting(s) from the heater core at the floor pan connection. 11. Remove the muffler. 12. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield. 13. Remove the 3 muffler heat shield bolts and the muffler heat shield. 14. Remove the 2 exhaust hanger bolts and the exhaust hanger. 15. Remove the RH Catalyst Monitor Sensor (CMS). 16. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield. 17. Remove the 3 remaining auxiliary line bracket nuts and the line brackets. 18. NOTE: If installing only one auxiliary heater line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5922 Expedition EL or Navigator L only 19. Remove the center section(s) of the auxiliary heater line(s) through the RH rear wheel well opening between the body and the frame. Expedition or Navigator only 20. Remove the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the front of the vehicle between the RH catalytic converter and frame. All vehicles 21. Remove the remaining auxiliary heater inlet and outlet line pieces. Installation All vehicles 1. Install the rear portion of the auxiliary heater outlet and inlet line(s) and connect the quick disconnect fittings. 2. Install the front auxiliary heater line(s) and connect the quick disconnect fittings. Expedition EL or Navigator L only 3. NOTE: Loosely connect, but do not tighten, the fittings. Install the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the front of the vehicle through RH rear wheel well opening between the body and the frame. Expedition or Navigator only 4. NOTE: Loosely connect, but do not tighten, the fittings. Install the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the rear of the vehicle through the opening between the RH catalytic converter and frame. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Evaporator Outlet and Inlet Line > Page 5923 All vehicles 5. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts. - Tighten to 5 Nm (44 lb-in). 6. Tighten the middle auxiliary heater line fittings. 7. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed. 8. Install the RH catalytic converter heat shield and the 3 catalytic converter heat shield rear bolts. 9. Install the RH CMS. 10. Install the exhaust hanger and the 2 exhaust hanger bolts. 11. Install the muffler heat shield and the 3 muffler heat shield bolts. 12. Install the muffler. 13. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts. 14. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt. 15. Install the front auxiliary line bracket and the front auxiliary line bracket and nut. - Tighten to 5 Nm (44 lb-in). 16. Install the RH front fender splash shield. 17. Install the RH front wheel and tire. Expedition EL or Navigator L only 18. Install the RH rear wheel and tire. All vehicles 19. Install the spare tire. 20. Fill the engine cooling system. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 must be vacuum leak tested before it is removed from the vehicle. 1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. 4. Disconnect the 2 heater hose quick disconnect fittings at the heater core. 5. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting. - Discard the gasket seals. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5928 - To install, tighten to 15 Nm (133 lb-in). 6. Remove the 3 heater core and evaporator core housing nuts. - To install, tighten to 7 Nm (62 lb-in). 7. Detach the 4 satellite radio antenna cable pin-type retainers from the heater core and evaporator core housing (if equipped). 8. Detach the 3 body harness electrical connectors from the bracket below the air inlet duct. 9. Remove the air inlet duct bracket nut. - To install, tighten to 7 Nm (62 lb-in). 10. Remove the plenum chamber nut. - To install, tighten to 7 Nm (62 lb-in). 11. Remove the 4 tunnel instrument panel bracket bolts and the tunnel instrument panel bracket. 12. Detach the rear footwell duct from the heater core and evaporator core housing. 13. Remove the heater core and evaporator core housing. 14. To install, reverse the removal procedure. - Install new gasket seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 15. Fill the engine coolant level. 16. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5929 Housing Assembly HVAC: Service and Repair Plenum Chamber Plenum Chamber Removal and Installation 1. Remove the heater core and evaporator core housing. For additional information, refer to Heater Core And Evaporator Core Housing See: Heater Core And Evaporator Core Housing. 2. Disconnect the mode door actuator electrical connector and position the wire harness aside. 3. Remove the 8 plenum chamber screws. 4. Release the plenum chamber clip and remove the plenum chamber. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5930 Housing Assembly HVAC: Service and Repair Auxiliary Heater Core and Evaporator Core Housing Auxiliary Heater Core and Evaporator Core Housing - Expedition, Navigator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Drain the engine coolant. 4. Remove the RH quarter trim panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5931 5. NOTE: Allow any residual coolant to drain from the auxiliary heater core after disconnecting the auxiliary heater hose fittings. Position a suitable drain pan and disconnect the 2 auxiliary heater hose fittings from the heater core at the floorpan connection. 6. Disconnect the 2 auxiliary evaporator line fittings at the floorpan connection. - Discard the O-ring seals. 7. Remove the 2 floorpan bracket bolts. 8. Remove the auxiliary headliner duct pin-type retainer and disconnect the duct. 9. Disconnect the auxiliary mode door actuator electrical connector. 10. Disconnect the auxiliary temperature blend door actuator electrical connector. 11. Disconnect the auxiliary blower motor resistor electrical connector. 12. Disconnect the auxiliary blower motor electrical connector and detach the wire harness from the housing. 13. Remove the 2 auxiliary heater core and evaporator core housing bolts. - To install, tighten to 8 Nm (71 lb-in). 14. Remove the auxiliary 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 the engine cooling system. 17. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5932 Housing Assembly HVAC: Service and Repair Auxiliary Heater Core and Evaporator Core Housing - Expedition EL, Navigator L Auxiliary Heater Core and Evaporator Core Housing - Expedition EL, Navigator L Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Drain the engine coolant. 4. Remove the RH rear quarter trim panel. 5. NOTE: Allow any residual coolant to drain from the auxiliary heater core after disconnecting the auxiliary heater core fittings. Position a suitable drain pan and disconnect the 2 auxiliary heater core quick disconnect fittings from the heater core at the floorpan connection. 6. Remove the auxiliary evaporator outlet and inlet line rear fitting nut and disconnect the fitting. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5933 - Discard the gasket seals. - To install, tighten to 12 Nm (106 lb-in). 7. Disconnect the auxiliary climate control harness electrical connector. 8. Remove the auxiliary airflow duct bolt. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 heater core and evaporator core housing bolts. - To install, tighten to 8 Nm (71 lb-in). 10. Remove the auxiliary heater core and evaporator core housing. 11. To install, reverse the removal procedure. - Install new gasket seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Fill the engine coolant level. 13. Evacuate, leak test and charge the refrigerant system. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation Air Conditioning Receiver/Drier NOTE: Installation of a new receiver/drier cartridge 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 receiver/drier cartridge. Damage to the receiver/drier cartridge includes physical damage 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 one hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the receiver/drier cartridge does not need to be replaced. The receiver/drier is integral to the A/C condenser/power steering combo cooler. It stores high-pressure liquid after it leaves the condenser core. An A/C desiccant cartridge mounted inside the receiver/drier removes any retained moisture from the refrigerant. The receiver/drier desiccant cartridge is a separate component and can be removed and installed separately from the A/C condenser/power steering combo cooler. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 5937 Receiver Dryer: Service and Repair Receiver Drier Cartridge Removal and Installation NOTE: Installation of a new receiver/drier desiccant cartridge 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 receiver/drier desiccant cartridge. Damage to the receiver/drier desiccant cartridge includes physical damage to the receiver/drier desiccant cartridge 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 one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the receiver/drier desiccant cartridge should not be replaced. 1. Remove the condenser core. For additional information, refer to Condenser Core See: Condenser HVAC/Service and Repair. 2. Unscrew and remove the plastic receiver/drier cap. 3. Remove the receiver/drier plug. 1. Push the receiver/drier plug upwards and remove the snap ring. 2. Install an M5 bolt in the center of the receiver drier plug and remove the plug. 4. Using a suitable tool, grasp the receiver/drier cartridge grab handle and remove the receiver/drier cartridge. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 5938 5. To install, reverse the removal procedure. - Lubricate the receiver/drier plug O-ring seals using residual refrigerant oil from inside the receiver/drier. Ford Expedition 2wd Workshop Manual (V8-5.4L (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.................................................................................................................... ...................................................................0.94 kg (33 oz) (2.07 lb) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5943 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.................................................................................................................... ...................................................................0.94 kg (33 oz) (2.07 lb) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5944 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5947 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5948 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5949 Refrigerant: Service and Repair Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new Thermostatic Expansion Valve (TXV), auxiliary system TXV (if equipped) 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/debris. 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 F8VZ-19E773-AB filter is intended for use on one vehicle only. 1. Remove the condenser core. 2. Remove the plastic receiver/drier cap. 3. Remove the receiver/drier plug. 1. Push the receiver/drier plug upwards and remove the snap ring. 2. Install an M5 bolt in the center of the receiver/drier plug and remove the plug. 4. Using a suitable tool, grasp the receiver/drier cartridge grab handle and remove the receiver/drier cartridge. 5. NOTE: Do not install a new receiver/drier cartridge at this time. With the receiver/drier cartridge removed, reinstall the receiver/drier plug and snap ring into the condenser core. 6. NOTE: Do not evacuate or charge the refrigerant system at this time. NOTE: The RH headlamp assembly must remain removed for access to the condenser outlet fitting. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5950 Install the condenser core back into the vehicle and completely reassemble the vehicle except for the condenser outlet fitting and RH headlamp assembly. 7. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit (219-00074) 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: Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. Using the correct adapters and service hoses, install the pancake filter between the condenser outlet and the condenser outlet fitting. 8. 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. 9. 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. 10. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Start the engine and allow it to idle briefly. Select A/C operation and set the blower speed to HI. Verify that the A/C is operating correctly. 11. If the vehicle is equipped with auxiliary A/C, set the auxiliary system to full COOL at HI blower speed. Verify that the auxiliary A/C is operating correctly. 12. 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. 13. Stop the engine. 14. 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. 15. Remove the pancake filter, hoses and adapter from the vehicle. 16. Remove the condenser core. 17. Remove and discard the receiver/drier plug snap ring and the receiver/drier plug. 18. Install a new receiver/drier cartridge. 19. NOTE: The vehicle should be fully assembled at the completion of this step. Install the condenser core. 20. Evacuate, leak test 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Item.........................................................................................................................................PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D Specification............................................... ..................................................................................................................................................WSHM1C231-B Fill Capacity........................................................................................................................ ......................................207 ml (7 fl oz) See: Service and Repair Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5955 Refrigerant Oil: Fluid Type Specifications Item.........................................................................................................................................PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D Specification............................................... ..................................................................................................................................................WSHM1C231-B Fill Capacity........................................................................................................................ ......................................207 ml (7 fl oz) See: Service and Repair Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5956 Refrigerant Oil: Service and Repair Refrigerant Oil Adding Refrigerant Oil Adding NOTICE: During normal Air Conditioning (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 refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Refer to the chart below for refrigerant oil adding amounts and methods of installation. a If an excessive amount of refrigerant oil is lost due to a hose rupture/separation or other damage, the total system refrigerant oil capacity must be added. b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the refrigerant oil amount by the number of O-ring leaks being repaired. Refrigerant Oil Adding for New A/C Compressor Without Clutch Installation NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. - Add the same amount plus the amount collected during refrigerant recovery. Refrigerant Oil Adding for New A/C Compressor With Clutch Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5957 1. 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. Oil Injection Using a Dye/Lubricant Injector NOTE: The dye/lubricant injector is included as part of the 219-00069 R-134a Loop/Add On Injector Kit-Set. 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 along with the refrigerant 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 using the correct adapters 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 new refrigerant compressor oil. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 5963 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 Expedition 2wd Workshop Manual (V8-5.4L (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 5964 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 5970 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 5971 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 5972 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5975 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5976 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5977 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5978 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5979 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5980 Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay 3 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 5981 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5985 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC > Page 5990 Control Module HVAC: Locations HVAC Module, DATC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EMTC > Page 5991 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC Control Module HVAC: Diagrams HVAC Module, DATC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 5994 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 5995 Control Module HVAC: Diagrams HVAC Module, EMTC Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 5996 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, DATC > Page 5997 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6002 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6003 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 6007 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 6008 Blower Motor Switch: Service and Repair Blower Motor Speed Control Removal and Installation 1. Remove the RH lower instrument panel insulator (if equipped). 2. Disconnect the blower motor speed control electrical connector. 3. Remove the 2 blower motor speed control screws. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6012 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6013 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the upper radiator sight shield. 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6016 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor In-Vehicle Temperature Sensor - Expedition 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6020 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6021 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning Evaporator Temperature Sensor / Switch: Description and Operation Air Conditioning Air Conditioning Evaporator Temperature Sensor The evaporator temperature sensor communicates the evaporator fin temperature to the HVAC module. The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the A/C compressor clutch when the evaporator temperature sensor reading falls below acceptable levels, and by engaging the A/C compressor clutch when the discharge air temperature rises above acceptable levels. The evaporator temperature sensor electrical connector is located outside of the heater core and evaporator core housing behind the glove compartment, with the sensor pigtail leading into the housing to the sensor probe which is inserted between the evaporator core fins. The evaporator temperature sensor is not available as a separate component. To install a new evaporator temperature sensor, a new heater core and evaporator core housing must be installed. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Air Conditioning > Page 6024 Evaporator Temperature Sensor / Switch: Description and Operation Engine Control Components 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 6025 Evaporator Temperature Sensor / Switch: Service and Repair Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor Removal and Installation 1. Detach the glove compartment dampener and lower the glove compartment. 2. Disconnect the evaporator discharge air temperature sensor electrical connector. 3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6031 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6032 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 6036 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 6037 Solar Sensor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 high-pressure side of the TXV manifold and tube at the RH rear of the engine compartment. The low-pressure service gauge port valve is located on the low-pressure side of the TXV manifold and tube at the RH rear of the engine compartment. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high-side and low-side service gauge ports. - A very small amount of leakage will always be detectable around the Schrader-type valve, with the service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively. - The service gauge port valve caps are used as primary seals in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 6044 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 6045 Solar Sensor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6051 - 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6052 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 portion, 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 Expedition 2wd Workshop Manual (V8-5.4L (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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 switch 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 portion 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. Make sure that all SRS components are connected. 2. Turn the ignition switch from OFF to ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6058 3. Install RCM fuse 32 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will illuminate 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. The flashing might not occur until approximately 30 seconds after the ignition 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 a 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 using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6059 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 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: 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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 portion 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. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column to allow for steering column upper and lower shroud removal. 9. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to the left from the straight-ahead position to access the driver air bag module wire clips and to prevent damage to the steering column multi-function switch. Failure to follow this instruction may result in component damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6060 Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position) as shown. 10. Remove the lower steering column opening cover. - Remove the 3 screws. - Pull out to release the top retainers. - Remove the lower steering column opening cover. If equipped, disconnect the adjustable pedals switch connector. 11. If equipped, remove the screw and steering column manual tilt lever. 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 15. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel. Failure to follow this instruction may result in component damage and/or system failure. NOTE: Steering wheel is removed for clarity. The rear of the steering wheel is shown. NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6061 16. NOTE: Once the driver air bag module is removed, note the position of the 2 driver air bag module locator pins on the steering wheel for installation. Disconnect the driver air bag module and horn switch electrical connectors and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight-ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door to allow access to the passenger air bag electrical connector. - If equipped, disconnect the glove compartment door dampener. 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat. The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical. 21. Release the RH second row safety belt retractor D-ring cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6062 22. Remove the bolt and the RH second row safety belt retractor D-ring. 23. Remove the cover and the RH C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the RH C-pillar trim panel. 25. Disconnect the RH safety canopy module electrical connector. 26. Release the LH second row safety belt retractor D-ring cover. 27. Remove the bolt and the LH second row safety belt retractor D-ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6063 28. Remove the cover and the LH C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver C-pillar trim panel. 30. Disconnect the LH safety canopy module electrical connector. 31. NOTE: There are 2 similar connectors under the driver seat. The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the Smart Junction Box (SJB). 33. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 32 (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 install the driver front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6064 4. Connect the LH safety canopy module electrical connector. 5. Install the LH C-pillar trim panel and attach the rear door weatherstrip. 6. Install the LH C-pillar trim panel nut and cover. 7. Install the LH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the LH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the RH safety canopy module electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6065 10. Install the RH C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger C-pillar trim panel nut and cover. 12. Install the RH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 13. Attach the RH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Extract and retract the safety belt between the full extension and stowed positions. - If excessive effort or binding is present, install a new safety belt buckle retractor and tongue assembly as necessary. For additional information, refer to Seat Belt Systems. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6066 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. NOTICE: The clockspring 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 horn switch and 2 driver air bag module electrical connectors. 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. NOTE: Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. 23. If equipped, install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. If equipped, connect the adjustable pedals switch connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6067 25. Install the lower steering column opening cover and 3 screws. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 32 (10A) to the SJB and install the cover. 28. 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. 29. 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 air bag SRS fault is present, the air bag warning indicator will either: - fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate 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 will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the RCM using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module Air Bag: Locations Driver Air Bag Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 6072 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 6073 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 6074 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 6075 Air Bag: Locations Passenger Air Bag Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 6076 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module Air Bag: Diagrams Driver Air Bag Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 6079 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 6080 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 6081 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 6082 Air Bag: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 6083 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 6084 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Module > Page 6085 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition Navigator Removal Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6088 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. 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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6089 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. Refer to Passenger Air Bag Module See: Passenger Air Bag Module. 8. NOTE: The video utilizes an F-Super Duty passenger air bag module assembly. It also applies to vehicles with similar passenger air bag module designs. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6090 Air Bag: Service and Repair Driver Air Bag Module Driver Air Bag Module NOTE: Expedition shown, Navigator similar. 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. 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. Make sure the road wheels are in the straight-ahead position. 2. Center the tilt steering column to allow for steering column upper and lower shroud removal. 3. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to the left from the straight-ahead position Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6091 to access the driver air bag module wire clips and to prevent damage to the steering column multifunction switch. Failure to follow this instruction may result in component damage. Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position). 4. 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 portion. 5. Remove the lower steering column opening cover. - Remove the 3 screws. - Pull out and release the top retainers. - Remove the lower steering column opening cover. If equipped, disconnect the adjustable pedals switch connector. 6. If equipped, remove the screw and steering column manual tilt lever. 7. Remove the 3 steering column lower shroud screws. 8. Release the clips and remove the steering column upper shroud. 9. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 10. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel. Failure to follow this instruction may result in component damage and/or system failure. NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. - Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6092 11. Disconnect the 2 driver air bag module electrical connectors, horn switch connector and remove the driver air bag module. 12. Turn the steering wheel so the top of the wheel is back in the straight ahead 12 o'clock position. Installation 1. Connect the horn switch connector and 2 driver air bag module connectors. 2. Position the driver air bag module to the steering wheel lining up the locator pins. 3. NOTE: For correct installation, make sure all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 4. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 5. Install the steering column upper shroud. 6. Install the 3 steering column lower shroud screws. 7. If equipped, install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6093 8. If equipped, connect the adjustable pedals switch connector. 9. Install the lower steering column opening cover and 3 screws. 10. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6094 Air Bag: Service and Repair Passenger Air Bag Module Passenger Air Bag Module Expedition Navigator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6095 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. 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 portion. 2. Lower the glove compartment door. 3. Disconnect the passenger air bag module electrical connector. Expedition vehicles 4. Remove the 4 passenger air bag trim cover screws. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6096 All vehicles 5. Remove the 4 passenger air bag module bolts. - To install, tighten to 9 Nm (80 lb-in). 6. Push out on the bottom of the passenger air bag cover to release the bottom trim cover clips from the instrument panel and remove the passenger air bag module. 7. NOTE: For correct installation, make sure all 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6097 Air Bag: Service and Repair Safety Canopy Module Safety Canopy Module NOTE: Expedition shown, other models 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 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 obstruct or place objects in the deployment path of the Safety Canopy(R) or side air curtain module. Failure to follow this Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6098 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 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 portion. 2. Remove the headliner. Vehicles with a moonroof 3. Disconnect the moon roof rear drain hose and release the drain hose retainer from the coat hook bracket. All vehicles 4. Disconnect the safety canopy module electrical connector. 5. NOTE: Note the locator tab on the front tether anchor bracket to the A-pillar sheet metal for installation. Remove the front tether bolt and bracket from the A-pillar. 6. Remove the 2 front tether cord pin-type retainers from the A-pillar sheet metal. 7. Remove the 2 safety canopy module front bolts and the one B-pillar bracket bolt. Expedition/Navigator vehicles 8. Detach the safety canopy module rear tether cord routing clip pin-type retainer from the sheet metal. 9. NOTE: Note the locator tab on the rear tether cord anchor bracket to the D-pillar sheet metal for installation. Remove the bolt and the safety canopy module rear tether cord anchor bracket from the D-pillar. Expedition EL/Navigator L vehicles 10. Detach the 3 safety canopy module rear tether cord routing clip pin-type retainers from the sheet metal. 11. NOTE: Note the locator tab on the rear tether cord anchor bracket to the D-pillar sheet metal for installation. Remove the bolt and the safety canopy module rear tether anchor bracket from the D-pillar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6099 All vehicles 12. Remove the C-pillar safety canopy module bolt. 13. Remove the 2 safety canopy module rear bolts and the roof bracket bolt. 14. Gently lift the safety canopy module up and inward at the B-pillar to release the bracket hook from the sheet metal. 15. Move the safety canopy module forward to release the rear bracket hook from the sheet metal and remove the safety canopy module. Installation All vehicles 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: 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. WARNING: Inspect a Safety Canopy(R) or side air curtain module before installation. If the module is damaged, the cover has separated or the Safety Canopy(R) or side air curtain material has been exposed, install a new module. Do not attempt to repair the module. 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. 1. Position the safety canopy module by moving it rearward, installing the rear bracket hook in the sheet metal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6100 2. Install the safety canopy module B-pillar bracket hook in the sheet metal. 3. Install the safety canopy module B-pillar bracket bolt. - Tighten to 9 Nm (80 lb-in). 4. Install the safety canopy module roof bracket bolt. - Tighten to 9 Nm (80 lb-in). 5. Install the 2 safety canopy module rear bolts. - Tighten to 9 Nm (80 lb-in). 6. Install the C-pillar safety canopy module bolt. - Tighten to 9 Nm (80 lb-in). Expedition EL/Navigator L vehicles 7. Install the safety canopy module rear tether anchor bracket and bolt to the D-pillar. - Tighten to 9 Nm (80 lb-in). 8. Attach the 3 safety canopy module rear tether routing clip pin-type retainers to the sheet metal. Expedition/Navigator vehicles 9. Install the safety canopy module rear tether anchor bracket and bolt to the D-pillar. - Tighten to 9 Nm (80 lb-in). 10. Attach the safety canopy module rear tether routing clip pin-type retainer to the sheet metal. All vehicles 11. Install the 2 safety canopy module front bolts. - Tighten to 9 Nm (80 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6101 12. Install the 2 front tether pin-type retainers in the A-pillar sheet metal. 13. Install the front tether bracket and bolt in the A-pillar. - Tighten to 6 Nm (53 lb-in). 14. Connect the safety canopy module electrical connector. Vehicles with a moonroof 15. Connect the moonroof rear drain hose and attach the drain hose retainer to the coat hook bracket. All vehicles 16. Install the headliner. 17. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6102 Air Bag: Service and Repair Side Air Bag Module Side Air Bag Module NOTE: Driver seat shown, passenger similar. 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. 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 seat back pad, trim cover, side air bag module and nuts must be installed. The seat back frame should be replaced 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. 1. Move the seat to the full forward and highest 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 portion. 3. Release the seat backrest cover lower rear J-clip and unzip the 2 side zippers. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6103 4. NOTE: Note the position of the side air bag module locator pin to the seat backrest frame for installation. Remove the 2 side air bag module nuts. - To install, tighten to 10 Nm (89 lb-in). 5. Position the backrest foam aside and remove the side air bag module from the backrest frame. Then slide the side air bag module out of the seat backrest cover deployment chute. For correct installation, position the locator pin and mounting studs through the holes in the deployment chute and backrest frame. 6. WARNING: Check the seat side air bag deployment chute for damage. The deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. 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. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6107 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6108 Air Bag Control Module: Diagrams C310A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6109 C310B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6110 C310B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6111 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) NOTE: Seats removed for clarity. Removal 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. 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. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous Diagnostic Trouble Codes (DTCs) will result. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 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 NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is disabled. The RCM and Accessory Protocol Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6112 Interface Module (APIM) must be configured correctly to fully support 911 assist functionality. 1. When installing a new RCM, carry out the appropriate steps necessary for the PMI procedure. 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 Vehicles with center console 3. Remove the center console. Vehicles with bucket seats without center console 4. Position the carpet aside and remove the 3 RCM pushnut retainers and the RCM cover. All vehicles 5. Disconnect the small RCM electrical connector. 1. Push down to release the retaining tab. 2. While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1. Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2. Pull out and disconnect the large RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation All vehicles 1. 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. Install the RCM and 3 bolts. Tighten to 11 Nm (97 lb-in). 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6113 3. NOTICE: Putting the large Restraints Control Module (RCM) electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large electrical connector into the RCM. NOTICE: Do not push on the connector so that 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. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with bucket seats without center console 6. Install the 3 pushnut retainers and RCM cover. Vehicles with center console 7. Install the center console. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6114 All vehicles 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. 9. If a new RCM was installed, carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. 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 air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. 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 a 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 memory DTCs from the RCM. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6118 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6119 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. Center the tilt steering column to allow for steering column upper and lower shroud removal. 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 portion. 3. 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. 4. NOTICE: To prevent damage to the clockspring, make sure the road wheels are in the straight-ahead position. Remove the steering wheel. 5. Disconnect the clockspring electrical connector. 6. Remove the 2 screws and 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. Connect the clockspring electrical connector. 3. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6120 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, proceed to Step 5. 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. 4. Starting with the clockspring rotor wiring and connector in the 12 o'clock position, rotate the clockspring rotor clockwise through two and one-quarter to two and one-half revolutions until the clockspring rotor wiring and connector are in the 12 o'clock position. The clock spring is now centered. Verify that the clockspring is correctly centralized by observing that the clockspring rotor, wiring and connector are in the 12 o'clock position. 5. 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. 6. If a new clockspring was installed, remove the anti-rotation key. 7. 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. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor Impact Sensor: Locations Front Impact Severity Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6125 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6126 Impact Sensor: Locations Driver Side Impact Sensor, C-Pillar Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6127 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6128 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6129 Impact Sensor: Locations Passenger Side Impact Sensor, C-Pillar Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6130 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6131 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6132 Impact Sensor: Locations Driver Front Door, Side Impact Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6133 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6134 Impact Sensor: Locations Passenger Front Door, Side Impact Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6135 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 6138 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 6139 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 6140 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 6141 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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. NOTE: The front impact severity sensor is located on the bottom of the lower radiator support. 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 portion. 2. Disconnect the front impact severity sensor electrical connector. 3. 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 11 Nm (97 lb-in). 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6144 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar Side Impact Sensor - C-Pillar NOTE: Expedition/Navigator shown, Expedition EL/Navigator L similar. NOTE: RH side shown, LH side 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 Supplemental Restraint System (SRS) fuse is removed and the ignition is ON. NOTE: The 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 portion. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. Remove the bolt and second row safety belt retractor anchor. - To install, tighten to 40 Nm (30 lb-ft). 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar and release the retaining clips to gain access to the C-pillar side impact sensor. 6. Disconnect the side impact sensor electrical connector. 7. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6145 NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the bolt and side impact sensor. To install, tighten to 11 Nm (97 lb-in). 8. 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. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6146 Impact Sensor: Service and Repair Side Impact Sensor - Front Door Side Impact Sensor - Front Door NOTE: RH door shown, LH 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 portion. 2. Remove the front door trim panel. 3. Separate the weathershield from the door enough to access the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. Remove the 2 bolts and side impact sensor. 6. NOTICE: To prevent stripping the insert nuts, tighten the side impact sensor bolts only enough to retain the side impact sensor correctly. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6147 - Inspect the insert nut for damage. If the insert nut is damaged, install a new insert. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 similar. 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. Move the driver seat to the full forward and highest position. 2. Change to Ignition Off. Wait 1 minute. 3. Remove the seat position sensor and bracket bolt. 4. Unhook the seat position sensor and bracket from the seat track cross brace. 5. Disconnect the electrical connector and remove the seat position sensor and bracket. 6. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6155 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6156 Air Bag Control Module: Diagrams C310A Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6157 C310B Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6158 C310B Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6159 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) NOTE: Seats removed for clarity. Removal 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. 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. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous Diagnostic Trouble Codes (DTCs) will result. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 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 NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is disabled. The RCM and Accessory Protocol Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6160 Interface Module (APIM) must be configured correctly to fully support 911 assist functionality. 1. When installing a new RCM, carry out the appropriate steps necessary for the PMI procedure. 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 Vehicles with center console 3. Remove the center console. Vehicles with bucket seats without center console 4. Position the carpet aside and remove the 3 RCM pushnut retainers and the RCM cover. All vehicles 5. Disconnect the small RCM electrical connector. 1. Push down to release the retaining tab. 2. While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 6. Disconnect the large RCM electrical connector. 1. Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2. Pull out and disconnect the large RCM electrical connector. 7. Remove the 3 bolts and RCM. Installation All vehicles 1. 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. Install the RCM and 3 bolts. Tighten to 11 Nm (97 lb-in). 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6161 3. NOTICE: Putting the large Restraints Control Module (RCM) electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large electrical connector into the RCM. NOTICE: Do not push on the connector so that 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. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with bucket seats without center console 6. Install the 3 pushnut retainers and RCM cover. Vehicles with center console 7. Install the center console. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6162 All vehicles 8. 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. 9. If a new RCM was installed, carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. 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 air bag SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. 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 a 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 memory DTCs from the RCM. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 switch 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 portion 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. Make sure that all SRS components are connected. 2. Turn the ignition switch from OFF to ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6168 3. Install RCM fuse 32 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will illuminate 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. The flashing might not occur until approximately 30 seconds after the ignition 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 a 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 using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6169 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 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: 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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 portion 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. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column to allow for steering column upper and lower shroud removal. 9. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to the left from the straight-ahead position to access the driver air bag module wire clips and to prevent damage to the steering column multi-function switch. Failure to follow this instruction may result in component damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6170 Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position) as shown. 10. Remove the lower steering column opening cover. - Remove the 3 screws. - Pull out to release the top retainers. - Remove the lower steering column opening cover. If equipped, disconnect the adjustable pedals switch connector. 11. If equipped, remove the screw and steering column manual tilt lever. 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 15. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel. Failure to follow this instruction may result in component damage and/or system failure. NOTE: Steering wheel is removed for clarity. The rear of the steering wheel is shown. NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6171 16. NOTE: Once the driver air bag module is removed, note the position of the 2 driver air bag module locator pins on the steering wheel for installation. Disconnect the driver air bag module and horn switch electrical connectors and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight-ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door to allow access to the passenger air bag electrical connector. - If equipped, disconnect the glove compartment door dampener. 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat. The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical. 21. Release the RH second row safety belt retractor D-ring cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6172 22. Remove the bolt and the RH second row safety belt retractor D-ring. 23. Remove the cover and the RH C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the RH C-pillar trim panel. 25. Disconnect the RH safety canopy module electrical connector. 26. Release the LH second row safety belt retractor D-ring cover. 27. Remove the bolt and the LH second row safety belt retractor D-ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6173 28. Remove the cover and the LH C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver C-pillar trim panel. 30. Disconnect the LH safety canopy module electrical connector. 31. NOTE: There are 2 similar connectors under the driver seat. The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the Smart Junction Box (SJB). 33. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 32 (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 install the driver front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6174 4. Connect the LH safety canopy module electrical connector. 5. Install the LH C-pillar trim panel and attach the rear door weatherstrip. 6. Install the LH C-pillar trim panel nut and cover. 7. Install the LH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the LH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the RH safety canopy module electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6175 10. Install the RH C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger C-pillar trim panel nut and cover. 12. Install the RH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 13. Attach the RH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Extract and retract the safety belt between the full extension and stowed positions. - If excessive effort or binding is present, install a new safety belt buckle retractor and tongue assembly as necessary. For additional information, refer to Seat Belt Systems. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6176 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. NOTICE: The clockspring 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 horn switch and 2 driver air bag module electrical connectors. 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. NOTE: Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. 23. If equipped, install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. If equipped, connect the adjustable pedals switch connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6177 25. Install the lower steering column opening cover and 3 screws. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 32 (10A) to the SJB and install the cover. 28. 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. 29. 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 air bag SRS fault is present, the air bag warning indicator will either: - fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate 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 will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the RCM using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor 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 portion, 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. Position the third row seat backrest downward. 2. Release the seat backrest cover J-clips. 3. With the seat backrest cover and cushion positioned aside, remove the bolt and the child safety seat tether anchor. - To install, tighten to 15 Nm (133 lb-in). 4. WARNING: Always tighten the child safety seat tether anchor/bolt to specification. Failure to follow this instruction may result in the child's safety seat being incorrectly secured, which increases the risk of serious personal injury or death to the child in a sudden stop or crash. NOTE: Inspect the seat for damage. If the seat is found to be damaged, install new seat components. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 portion, 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. The safety belt retractor is designed to let the webbing move freely in and out at all times, except during vehicle hard braking, hard cornering or an impact of 24 km/h (15 mph) or more, when it is automatically locked by a mechanically actuated inertia sensor. When replacing safety belt buckles and/or retractor assemblies, 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 pretensioner is a pyrotechnic device that removes excess webbing from the front seat safety belt system. When the front air bag system is deployed, the pretensioner in the buckle deploys, causing the buckle to move downward, pulling excess webbing from the lap and shoulder safety belts. If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt pretensioners, the driver and passenger seat belt system (including safety belt buckle and pretensioners, safety belt retractors and shoulder height adjusters) must be replaced. For safety belt buckle pretensioner diagnosis and disposal information, refer to Air Bag Systems. Rear Safety Belt Buckles The second row seat safety belt buckles and third row RH safety belt buckle are attached to the seat frames. The third row LH and center safety belt buckle assembly is attached to the floor pan underneath the 60 percent seat. All rear safety belt buckles are serviceable separately. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation > Page 6185 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 portion, 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, 20 Percent Seat Safety Belt Buckle - Second Row, 20 Percent Seat 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 portion, 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. Position the seat upright. 2. Remove the nut and safety belt buckle from underneath the seat. - To install, tighten to 55 Nm (41 lb-ft). 3. NOTE: When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 6188 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, 40 Percent Seat Safety Belt Buckle - Second Row, 40 Percent Seat NOTE: RH shown, LH similar. 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 portion, 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. Pivot the 40 percent seat upward. 2. Remove the rearward screw (not shown) and seat side shield. - Release the pin-type retainer (not shown). 3. Remove the bolt and safety belt buckle. - To install, tighten to 50 Nm (37 lb-ft). 4. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 6189 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Third Row, 40 Percent Seat Safety Belt Buckle - Third Row, 40 Percent Seat 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 portion, 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 third row 40 percent seat. 2. Remove the bolt and safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: 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 in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 6190 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Third Row, 60 Percent Seat Safety Belt Buckle - Third Row, 60 Percent Seat 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 portion, 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. Fold the 60 percent seat down. 2. Position the load floor panels up. 3. Remove the bolt and safety belt buckle assembly. - To install, tighten to 40 Nm (30 lb-ft). 4. Fold the 60 percent seat up and remove the safety belt buckle assembly through the seat. 5. NOTE: 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. 6. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 6191 Seat Belt Buckle: Service and Repair Safety Belt Buckle And Pretensioner Safety Belt Buckle and Pretensioner Driver Safety Belt Buckle and Pretensioner Passenger Safety Belt Buckle and Pretensioner 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, 20 Percent Seat > Page 6192 - 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 portion, 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 seat. 2. Release the hook-and-loop strip and pull the seat cushion trim cover up enough to expose the safety belt buckle and pretensioner. 3. Remove the tie strap from the pretensioner. - Disconnect the electrical connector(s). - Note wire harness routing for correct installation. 4. Remove the nut and safety belt buckle and pretensioner. - To install, tighten to 55 Nm (41 lb-ft). 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6196 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: RH shown, LH similar. 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 portion, 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 damaged or does not remain closed, install a new D-ring cover and bolt. Position the safety belt guide to the lowest position. Remove the upper B-pillar trim panel. 2. Access the bolt behind the safety belt shoulder height adjuster cover in the following sequence. - Lower the safety belt shoulder height adjuster to the lowest point. - Fold the cover over. 3. Remove the safety belt shoulder height adjuster bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. Remove the safety belt shoulder height adjuster. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6200 1. Rotate the safety belt shoulder height adjuster downward to release the lower tab. 2. Remove the safety belt shoulder height adjuster. 5. NOTE: 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. 6. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Service and Repair Seat Belt Reminder Buzzer: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation 1. Set the parking brake. 2. Place the transmission in PARK (P). 3. Turn the ignition switch to the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and passenger safety belts. Deactivating/Activating 1. Turn the ignition switch to the RUN 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 or the procedure must be repeated. Buckle then unbuckle the safety belt 9 times, ending with the safety belt unbuckled. 4. NOTE: After Step 3, the safety belt warning indicator lamp illuminates for 3 seconds. Within 10 seconds of the safety belt warning indicator turning on, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature 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 if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by a second series of 4 flashes per second for 3 seconds. 5. After confirmation, the deactivation/activation procedure is complete. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Service and Repair Seat Belt Reminder Lamp: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation 1. Set the parking brake. 2. Place the transmission in PARK (P). 3. Turn the ignition switch to the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and passenger safety belts. Deactivating/Activating 1. Turn the ignition switch to the RUN 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 or the procedure must be repeated. Buckle then unbuckle the safety belt 9 times, ending with the safety belt unbuckled. 4. NOTE: After Step 3, the safety belt warning indicator lamp illuminates for 3 seconds. Within 10 seconds of the safety belt warning indicator turning on, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature 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 if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by a second series of 4 flashes per second for 3 seconds. 5. After confirmation, the deactivation/activation procedure is complete. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 portion, 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. The safety belt retractor is designed to let the webbing move freely in and out at all times, except during vehicle hard braking, hard cornering or an impact of 24 km/h (15 mph) or more, when it is automatically locked by a mechanically actuated inertia sensor. When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Retractors The safety belt retractors are a dual locking mode type and consist of the following features: - Emergency Locking Retractor (ELR) - Automatic Locking Retractor (ALR) (all except driver seat) Safety Belt Retractor and Features Emergency Locking Retractor (ELR) The ELR is a vehicle sensitive feature designed to activate and lock the safety belt webbing when braking hard, cornering hard or in an impact of approximately 24 km/h (15 mph). The ELR feature helps to reduce the forward movement of the occupants. For testing, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. 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. When installing a dual locking mode retractor, the retractor should be checked to make sure it is not in the ALR mode after installation in the stowed position. Refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 portion, 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Functional Test - Safety Belt Retractor > Page 6212 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 portion, 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Functional Test - Safety Belt Retractor > Page 6213 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 portion, 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 Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: RH shown, LH similar. 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 portion, 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 damaged or does not remain closed, install a new D-ring cover. Remove the upper and lower B-pillar trim panels. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6216 2. Release the 2 pin-type retainers and safety belt guide. 3. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. NOTE: Remove the shipping clip after safety belt retractor installation. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6217 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row and Third Row, Outboard Safety Belt Retractor - Second Row and Third Row, Outboard Expedition/Navigator NOTE: RH shown, LH similar. Expedition EL/Navigator L NOTE: RH shown, LH similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6218 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 portion, 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. All retractors 1. Remove the rear quarter trim panel. Second row retractors 2. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install a new D-ring cover and bolt. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6219 Open the D-ring cover and remove the D-ring bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). Third row retractors 4. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install a new D-ring cover and bolt. Expedition and Navigator third row D-ring cover is serviced as part of the safety belt retractor assembly. If equipped, open the D-ring cover and remove the D-ring bolt. - To install, tighten to 40 Nm (30 lb-ft). 5. If equipped, remove the sling bolt cover and safety belt sling bolt. - To install, tighten to 40 Nm (30 lb-ft). 6. For RH third row safety belt retractor, remove the 2 screws and position aside the auxiliary relay box, if equipped. All retractors 7. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 8. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. NOTE: Before installing the third row safety belt anchor, make sure the floor-slotted plastic insert is still present. If it is not, another insert must be installed. To install, reverse the removal procedure. 9. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6220 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Center Safety Belt Retractor - Second Row, Center 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 portion, 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 retractor may be equipped with an additional web stop button (small, thin, round button, not to be confused with the larger web stop button) located on the safety belt webbing. This button is only used for vehicle assembly and serves no other functional purpose. The button can possibly be Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6221 retracted under the trim bezel, making it difficult to pull the safety belt webbing out of the retractor. To service, remove this web stop button. Do not install a new safety belt retractor to eliminate this condition. Any resulting appearance concerns with the webbing can be worked out by hand. For additional information, refer to Safety Belt System See: Description and Operation. 1. Remove the second row 20 percent seat backrest trim cover. 2. Remove the seat backrest foam pad. 3. Remove the safety belt retractor cover foam. 4. Remove the 2 screws from the seat belt retractor cover and remove the cover. 5. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 6. Pinch and release the safety belt retractor guide from the seat backrest frame and remove the safety belt retractor. 7. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. NOTE: Remove the shipping clip after safety belt retractor installation. To install, reverse the removal procedure. 8. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6222 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Third Row, Center Safety Belt Retractor - Third Row, Center 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 portion, 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 retractor may be equipped with an additional web stop button (small, thin, round button, not to be confused with the larger web stop button) located on the safety belt webbing. This button is only used for vehicle assembly and serves no other functional purpose. The button can possibly be Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6223 retracted under the trim bezel, making it difficult to pull the safety belt webbing out of the retractor. To service, remove this web stop button. Do not install a new safety belt retractor to eliminate this condition. Any resulting appearance concerns with the webbing can be worked out by hand. 1. Remove the third row 60 percent seat backrest trim cover. 2. Remove the seat backrest foam pad. 3. Remove the 4 screws from the safety belt retractor cover (2 shown). 4. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 5. Pinch to release the safety belt retractor guide and remove the safety belt retractor. 6. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. NOTE: Remove the shipping clip after safety belt retractor installation. To install, reverse the removal procedure. 7. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Safety Belt Buckle Pretensioner, Driver Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Safety Belt Buckle Pretensioner, Driver > Page 6228 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 6229 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 portion, 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. The safety belt retractor is designed to let the webbing move freely in and out at all times, except during vehicle hard braking, hard cornering or an impact of 24 km/h (15 mph) or more, when it is automatically locked by a mechanically actuated inertia sensor. When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Retractors The safety belt retractors are a dual locking mode type and consist of the following features: - Emergency Locking Retractor (ELR) - Automatic Locking Retractor (ALR) (all except driver seat) Safety Belt Retractor and Features Emergency Locking Retractor (ELR) The ELR is a vehicle sensitive feature designed to activate and lock the safety belt webbing when braking hard, cornering hard or in an impact of approximately 24 km/h (15 mph). The ELR feature helps to reduce the forward movement of the occupants. For testing, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. 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. When installing a dual locking mode retractor, the retractor should be checked to make sure it is not in the ALR mode after installation in the stowed position. Refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 6233 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor Impact Sensor: Locations Front Impact Severity Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6239 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6240 Impact Sensor: Locations Driver Side Impact Sensor, C-Pillar Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6241 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6242 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6243 Impact Sensor: Locations Passenger Side Impact Sensor, C-Pillar Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6244 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6245 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6246 Impact Sensor: Locations Driver Front Door, Side Impact Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6247 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6248 Impact Sensor: Locations Passenger Front Door, Side Impact Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Impact Severity Sensor > Page 6249 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 6252 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 6253 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 6254 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Front Impact Severity Sensor > Page 6255 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 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. NOTE: The front impact severity sensor is located on the bottom of the lower radiator support. 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 portion. 2. Disconnect the front impact severity sensor electrical connector. 3. 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 11 Nm (97 lb-in). 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 Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6258 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar Side Impact Sensor - C-Pillar NOTE: Expedition/Navigator shown, Expedition EL/Navigator L similar. NOTE: RH side shown, LH side 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 Supplemental Restraint System (SRS) fuse is removed and the ignition is ON. NOTE: The 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 portion. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip. 4. Remove the bolt and second row safety belt retractor anchor. - To install, tighten to 40 Nm (30 lb-ft). 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar and release the retaining clips to gain access to the C-pillar side impact sensor. 6. Disconnect the side impact sensor electrical connector. 7. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6259 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 C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Remove the bolt and side impact sensor. To install, tighten to 11 Nm (97 lb-in). 8. 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. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6260 Impact Sensor: Service and Repair Side Impact Sensor - Front Door Side Impact Sensor - Front Door NOTE: RH door shown, LH 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 portion. 2. Remove the front door trim panel. 3. Separate the weathershield from the door enough to access the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. Remove the 2 bolts and side impact sensor. 6. NOTICE: To prevent stripping the insert nuts, tighten the side impact sensor bolts only enough to retain the side impact sensor correctly. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6261 - Inspect the insert nut for damage. If the insert nut is damaged, install a new insert. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6265 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 similar. 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. Move the driver seat to the full forward and highest position. 2. Change to Ignition Off. Wait 1 minute. 3. Remove the seat position sensor and bracket bolt. 4. Unhook the seat position sensor and bracket from the seat track cross brace. 5. Disconnect the electrical connector and remove the seat position sensor and bracket. 6. 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 portion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 6272 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6278 Accessory Delay Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6279 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Locations Antenna Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Locations > Page 6284 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Locations > Page 6285 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Locations > Page 6286 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - AM/FM Antenna Cable: Service and Repair Antenna Cable - AM/FM Antenna Cable - AM/FM Removal and Installation Front AM/FM antenna cable 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). Rear AM/FM antenna cable 2. Remove the RH scuff plate. 3. Remove the RH A-pillar lower trim panel. Both AM/FM antenna cables 4. Disconnect the AM/FM antenna cable connection. 5. NOTE: The rear AM/FM antenna cable is an integral part of the wiring harness and cannot be replaced separately from the harness. Cut the ends off the old antenna cable and tape the remainder to the wiring harness to prevent noise. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - AM/FM > Page 6292 Remove the AM/FM antenna cable. 6. NOTE: When installing a new rear AM/FM antenna cable, tape or wire-tie the new cable to the wiring harness to prevent noise. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - AM/FM > Page 6293 Antenna Cable: Service and Repair Antenna Cable - Satellite Radio Antenna Cable - Satellite Radio Removal and Installation 1. Remove the RH A-pillar trim panel. 2. Remove the RH sun visor. 3. Lower the front of the headliner enough to gain access to the satellite radio antenna electrical connector. 4. Disconnect the satellite radio antenna electrical connector. 5. Remove the satellite radio antenna. - Disconnect the satellite radio antenna cable-to-Satellite Digital Audio Receiver System (SDARS) module electrical connector. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 wheel. 2. Remove the 2 screws and the lower steering column shroud. 3. Disconnect the Passive Anti-Theft System (PATS) transceiver electrical connector. 4. Remove the screw and the PATS transceiver. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations Hood Sensor/Switch (For Alarm): Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6304 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6305 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 6310 Keyless Entry Key-Pad: Testing and Inspection Keyless Entry Keypad Code Programming Programming a Personal Code and Keypad Association to Memory Seats and Mirrors (If Equipped) NOTE: If the wrong code has been entered 7 times (35 consecutive button presses), the keypad will go into an anti-scan mode. This mode disables the keypad for one minute and the keypad illumination will flash. The anti-scan feature will turn off after one minute of keypad inactivity, after pressing the UNLOCK button on the Remote Keyless Entry (RKE) transmitter, or after the ignition key has been turned to the ON position. NOTE: The factory set code cannot be associated with a memory setting. 1. Enter the permanent factory keyless entry keypad code. 2. Within 5 seconds, press the 1/2 button on the keypad. 3. Enter the new 5-digit keyless entry keypad code. Each number must be entered within 5 seconds of each other. 4. To associate the entry code with a memory setting, enter a sixth digit to indicate which driver should be set in a memory recalled by the personal entry code: Pressing the 1/2 button recalls driver 1 settings - Pressing the 3/4 button recalls driver 2 settings - Pressing other keypad buttons or not pressing a keypad button as a sixth digit does not set a driver and will not recall a memory setting 5. The doors will lock then unlock to confirm the new code is programmed. Erasing the Personal Codes NOTE: If the wrong code has been entered 7 times (35 consecutive button presses), the keypad will go into an anti-scan mode. This mode disables the keypad for one minute and the keypad illumination will flash. The anti-scan feature will turn off after one minute of keypad inactivity, after pressing the UNLOCK button on the RKE transmitter, or after the ignition key has been turned to the ON position. 1. Enter the permanent factory keyless entry keypad code. 2. Within 5 seconds, press the 1/2 button on the keypad and release. 3. Within 5 seconds, press and hold the 1/2 button on the keypad for 2 seconds. 4. All personal codes are now erased and only the permanent factory keyless entry keypad code will work. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 6311 Keyless Entry Key-Pad: Service and Repair Keyless Entry Keypad Removal and Installation 1. Remove the exterior mirror. 2. Remove the front door outer glass weatherstrip. - Disconnect the electrical connector. 3. Release the tabs and remove the keyless entry keypad. - Disconnect the keypad harness retaining clips from the weatherstrip. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: This procedure is for programming conventional keyfobs only. The Remote Keyless Entry (RKE) transmitter of the Integrated Keyhead Transmitter (IKT) is programmed automatically during the Passive Anti-Theft System (PATS) programming. For additional information, refer to Key Programming Using Two Programmed Keys or Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment in Antitheft and Alarm Systems to program the IKT. See: Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys See: Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: All RKE transmitters must be programmed at the same time. NOTE: Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the transmitters will not be programmed. 1. Electronically unlock the door locks using the door lock control switch. 2. Cycle the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10 seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the programming sequence ends (the doors lock and unlock to confirm that programming is complete). Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (4) of RKE transmitters have been programmed. 5. Check the operation of the RKE transmitter. If the door locks do not respond for the programmed RKE transmitter(s), 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 RKE transmitters are attempted to be programmed.) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6316 Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming Autolock and Auto-Unlock Programming Programming the Autolock Feature Using the Door Lock Control Switch NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped. NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door lock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock and lock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the unlock button and then the lock button on the door lock control switch within 5 seconds to enable/disable the autolock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Auto-Unlock Feature Using the Door Lock Control Switch NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped. NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the lock button on the door lock control switch then the unlock button to enable/disable the auto-unlock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Autolock Feature Using the Keyless Entry Keypad NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure needs to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6317 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button. 4. Release the 3/4 button. The horn chirps once if the autolocks are disabled, or chirps once followed by a honk if the autolocks are enabled. Programming the Auto-Unlock Feature Using the Keyless Entry Keypad NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button twice. 4. Release the 3/4 button. The horn chirps once if auto-unlock is disabled, or chirps once followed by a honk if auto-unlock is enabled. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6318 Keyless Entry Transmitter: Testing and Inspection Remote Memory Activation Remote Memory Activation 1. Position the driver seat, adjustable pedals, steering column and exterior mirror to the desired positions. 2. Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds when the memory store is done. Continue to hold until a second tone is heard after 5 seconds. 3. Within 3 seconds, press the LOCK button on the Remote Keyless Entry (RKE) transmitter. 4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6319 Keyless Entry Transmitter: Testing and Inspection Remote Memory Deactivation Remote Memory Deactivation 1. Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds when the memory store is done. Continue to hold until a second tone is heard after 5 seconds. 2. Within 3 seconds, press the UNLOCK button on the Remote Keyless Entry (RKE) transmitter. 3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE transmitter. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6320 Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter Programming Remote Keyless Entry (RKE) Transmitter Programming NOTE: This procedure is for programming conventional keyfobs only. The Remote Keyless Entry (RKE) transmitter of the Integrated Keyhead Transmitter (IKT) is programmed automatically during the Passive Anti-Theft System (PATS) programming. For additional information, refer to Key Programming Using Two Programmed Keys or Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment in Antitheft and Alarm Systems to program the IKT. See: Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys See: Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: All RKE transmitters must be programmed at the same time. NOTE: Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the transmitters will not be programmed. 1. Electronically unlock the door locks using the door lock control switch. 2. Cycle the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10 seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the programming sequence ends (the doors lock and unlock to confirm that programming is complete). Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (4) of RKE transmitters have been programmed. 5. Check the operation of the RKE transmitter. If the door locks do not respond for the programmed RKE transmitter(s), 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 RKE transmitters are attempted to be programmed.) Autolock and Auto-Unlock Programming Autolock and Auto-Unlock Programming Programming the Autolock Feature Using the Door Lock Control Switch NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped. NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door lock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock and lock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the unlock button and then the lock button on the door lock control switch within 5 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6321 seconds to enable/disable the autolock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Auto-Unlock Feature Using the Door Lock Control Switch NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped. NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the lock button on the door lock control switch then the unlock button to enable/disable the auto-unlock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Autolock Feature Using the Keyless Entry Keypad NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure needs to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button. 4. Release the 3/4 button. The horn chirps once if the autolocks are disabled, or chirps once followed by a honk if the autolocks are enabled. Programming the Auto-Unlock Feature Using the Keyless Entry Keypad NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button twice. 4. Release the 3/4 button. The horn chirps once if auto-unlock is disabled, or chirps once followed by a honk if auto-unlock is enabled. Remote Memory Activation Remote Memory Activation Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6322 1. Position the driver seat, adjustable pedals, steering column and exterior mirror to the desired positions. 2. Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds when the memory store is done. Continue to hold until a second tone is heard after 5 seconds. 3. Within 3 seconds, press the LOCK button on the Remote Keyless Entry (RKE) transmitter. 4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Remote Memory Deactivation Remote Memory Deactivation 1. Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds when the memory store is done. Continue to hold until a second tone is heard after 5 seconds. 2. Within 3 seconds, press the UNLOCK button on the Remote Keyless Entry (RKE) transmitter. 3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE transmitter. Perimeter Lighting Feature Programming Perimeter Lighting Feature Programming Programming the Perimeter Lighting Feature Using the Door Lock Control Switch NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the ON position. 2. Press the unlock button on the door lock control switch 3 times. 3. Turn the ignition switch from the ON to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the ON position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock button must be pressed twice within 5 seconds. Within 30 seconds of entering the programming mode, press the unlock button on the door lock control switch twice to enable/disable the perimeter lighting feature. The horn chirps once if the perimeter lighting is disabled or a chirp followed by a honk if the perimeter lighting is enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. 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 turn signals flash twice to indicate the mode change. 2. Repeat Step 1 to enable/disable the stepped unlocking feature. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6332 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6333 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6334 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6335 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6336 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6337 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6338 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6339 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6340 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6345 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6346 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6347 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6348 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6349 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6350 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6351 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6352 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6353 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6354 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6355 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6361 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6362 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6363 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6364 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6365 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6366 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6367 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6368 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6369 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6374 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6375 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6376 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6377 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6378 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6379 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6380 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6381 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6382 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6383 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6384 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 6397 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 6398 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 6403 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 6404 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 6414 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 6415 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 6420 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > 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 6421 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) Communications Control Module: Locations Accessory Protocol Interface Module (APIM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6424 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6425 Communications Control Module: Locations Audio Control Module (ACM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6426 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6427 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6430 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6431 Communications Control Module: Diagrams Audio Control Module (ACM) Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6432 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6433 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6434 Communications Control Module: Diagrams Audio Digital Signal Processing (DSP) Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6435 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6436 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6439 - 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6440 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6441 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6442 Communications Control Module: Removal and Replacement Audio Digital Signal Processing (DSP) Module Audio Digital Signal Processing (DSP) Module Audio Digital Signal Processing (DSP) Module Lower Attachment Audio DSP Module Upper Attachment Audio DSP Module Removal Routing Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6443 Removal and Installation 1. NOTE: Module configuration is required when a new audio Digital Signal Processing (DSP) module is being installed. Upload the audio DSP module configuration information to the scan tool. 2. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control Module (ACM) See: Audio Control Module (ACM). 3. Remove the necessary attachments and move the center console 5 cm (2.0 in) towards the rear of the vehicle. 4. Disconnect the audio DSP module electrical connectors. 5. Remove the 2 lower audio DSP module nuts. - To install, tighten to 9 Nm (80 lb-in). 6. NOTICE: The audio Digital Signal Processing (DSP) module is heavy. Be sure to support the amplifier during removal, or damage to the vehicle may occur. Remove the 2 upper audio DSP module nuts. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the audio DSP module. - Route the audio DSP module down and towards the passenger side of the vehicle. 8. To install, reverse the removal procedure. - Download the configuration information to the audio DSP module. Audio Control Module (ACM) Audio Control Module (ACM) NOTE: Expedition without navigation shown, all others similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6444 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 electrical connectors and the antenna cable connector. 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6445 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. 2. Remove the front floor console. 3. Remove the 4 APIM screws and position the APIM aside. 4. Disconnect the Universal Serial Bus (USB) cable and the electrical connectors, and remove the APIM. 5. 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 Removal and Installation 1. Remove the floor console. 2. Remove the rear cupholder trim panel by pulling straight upward to disengage the clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6446 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6451 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6452 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6453 Parking Assist Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6454 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6455 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6456 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) - Expedition Removal and Installation 1. Disconnect the Parking Aid Module (PAM) sub-harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the sub-harness from the PAM. 5. Remove the 2 PAM bracket bolts. 6. Remove the PAM bracket assembly. 7. Release the module tabs from the bracket and remove the module from the bracket. 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6461 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6462 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6463 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6464 Parking Assist Distance Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6465 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6466 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6467 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6468 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6469 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6470 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Front Outer Left > Page 6471 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 6474 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 6475 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 6476 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 6477 Parking Assist Distance Sensor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 6478 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 6479 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor Front Outer Left > Page 6480 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Parking Aid Sensor - Front Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Front Parking Aid Sensor - Front Sedan Removal and Installation 1. Remove the front bumper cover. 2. Disconnect the parking aid sensor electrical connectors. 3. NOTE: Press the retaining tabs to release the sensor(s). Remove the parking aid sensor(s). 4. To install, reverse the removal procedure. - NOTICE: Paint the new sensor(s) with base coat and one coat of clear. Excessive paint film buildup may result in incorrect sensor operation. Using the scan tool, verify that the parking aid sensor PIDs read no object present, and that the parking aid sensor attenuation PIDs read between 0.8-1.6 ms. If the parking aid sensor attenuation PIDs do not read between 0.8-1.6 ms, the paint is too thick on the sensor(s) and it will be necessary to repaint the sensor(s) as required. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Parking Aid Sensor - Front > Page 6483 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Rear Parking Aid Sensor - Rear Removal and Installation 1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor electrical connectors. 3. NOTE: Press the retaining tabs to release the sensor(s). Remove the parking aid sensor(s). 4. To install, reverse the removal procedure. - Using the scan tool, verify that the parking aid sensor PIDs read no object present, and that the parking aid sensor attenuation PIDs read between 0.8-1.6 ms. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams > Parking Aid Speaker Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams > Parking Aid Speaker Front > Page 6488 Parking Assist Warning Indicator: Diagrams Parking Aid Speaker Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams > Page 6489 Parking Assist Warning Indicator: Service and Repair Parking Aid Speaker - Expedition Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the bolt and the speaker and bracket assembly. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams Rear Vision Camera: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams > Page 6493 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams > Page 6494 Rear Vision Camera: Service and Repair Video Camera Expedition Navigator Removal and Installation All vehicles 1. Remove the liftgate trim panel. - Position the water shield aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams > Page 6495 Expedition 2. Remove the 4 nuts and the license lamp housing. - Disconnect the electrical connector. 3. Squeeze release tabs and remove the video camera and bracket from the license lamp housing. Navigator 4. Remove the liftgate parking lamps. 5. Remove the 6 nuts and the license plate housing. - Disconnect the electrical connector. 6. Remove the 2 screws and the video camera bracket. All vehicles 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations Driver/Vehicle Information Display: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 6499 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 6500 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Oil Life Reset - Message Center Cluster Message Center Configuration Oil Life Reset - Message Center Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset - Base Instrument Cluster (IC) Message Center Configuration Oil Life Reset - Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value - Message Center Cluster Message Center Configuration Oil Life Start Value - Message Center Cluster NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value - Base Instrument Cluster (IC) Message Center Configuration Oil Life Start Value - Base Instrument Cluster (IC) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 6503 NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 6504 Driver/Vehicle Information Display: Removal and Replacement Message Center Switch Expedition Navigator Removal and Installation Expedition 1. Pull the instrument panel center finish panel straight out to release the retaining clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 6505 Navigator 2. NOTE: The transmission selector lever bezel is held in place by 4 tabs that are located in the shifter assembly. Remove the transmission selector lever bezel. 3. Open the floor console compartment door and pull the floor console finish panel straight up to release the retainer clips. 4. Remove the 2 screws and pull the instrument panel center finish panel straight out to release the retainer clips. - Position the instrument panel center finish panel aside. All vehicles 5. Disconnect the electrical connectors. 6. Press the 4 retaining tabs and remove the message center switch from the center instrument panel finish panel. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6514 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6515 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6520 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6521 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6522 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6523 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6524 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6525 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6526 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6527 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6528 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6529 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6530 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6536 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6537 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6542 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6543 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6544 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6545 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6546 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6547 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6548 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6549 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6550 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6551 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6552 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6557 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > 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 6558 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6564 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6565 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Page 6570 Auxiliary Input / Output Jack: Service and Repair Audio Input Jack NOTE: Vehicle with the SYNC system shown, others similar. Removal and Installation 1. Open the floor console stowage bin door. 2. Using a suitable flat-bladed tool, remove the audio input jack bezel by prying straight upward. - Disconnect the audio input jack electrical connector and the Universal Serial Bus (USB) cable, if equipped. 3. Release the tabs and remove the audio input jack. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) Entertainment System Control Module: Locations Rear Entertainment Module (RETM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 6586 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 6587 Entertainment System Control Module: Locations Audio Rear Control Unit (RCU) Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 6588 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) > Page 6591 Entertainment System Control Module: Diagrams Audio Rear Control Unit (RCU) Module Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) > Page 6592 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. NOTE: Module configuration is required when a new Rear Entertainment Module (RETM) is being installed. Upload the RETM configuration to the scan tool. 2. NOTE: Open the video 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Panel > Component Information > Service and Repair > Page 6596 7. Push on the left and right sides of the RETM to engage the clips. 8. Download the configuration information to the RETM configuration. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation Universal Transmitter The universal transmitter is an integral part of the LH sun visor and 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Universal Transmitter 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 fault is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6602 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures Universal Transmitter Symptom Chart Symptom Chart Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6603 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 The universal transmitter receives voltage with the key in the ON position on circuit CLN09 (YE/GN) and ground on circuit GD138 (BK/WH). This pinpoint test is intended to diagnose the following: - Universal transmitter - Receiver unit PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE ------------------------------------------------- A1 CHECK THE LEFT VANITY MIRROR OPERATION - Check the illumination of the left vanity mirror lamps. - Do the left vanity mirror lamps illuminate? Yes GO to A2. No REFER to Courtesy Lamp. See: Lighting and Horns/Courtesy Lamp/Testing and Inspection ------------------------------------------------- A2 PROGRAM A HAND-HELD TRANSMITTER INTO THE UNIVERSAL TRANSMITTER - NOTE: If the garage door is equipped with rolling codes, refer to Training a Garage Door Opener Equipped With "Rolling Codes". - 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 unit operates correctly. No INSTALL a new LH sun visor assembly. TEST the system for normal operation. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6604 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6614 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6615 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6621 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6622 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6627 Memory Positioning Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6628 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6629 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6630 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6631 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. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed, it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 6635 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6645 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6646 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6652 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6653 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Pedal Positioning Motor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 6658 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 6659 Pedal Positioning Motor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 6660 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 6664 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 6665 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 6668 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 6669 Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 6670 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 6676 Amplifier: Diagrams Audio Amplifier Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 6677 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6678 Amplifier: Service and Repair Audio Amplifier 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. Disconnect the audio amplifier electrical connectors. 3. Remove the 3 bolts and the audio amplifier. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations Radio/Stereo: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations > Page 6695 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations > Page 6696 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Audio Rear Control Unit (RCU) Module Radio/Stereo: Service and Repair Audio Rear Control Unit (RCU) Module Audio Rear Control Unit (RCU) Module NOTE: Expedition shown, Navigator similar. Removal and Installation All vehicles 1. NOTE: Module configuration is required when a new audio Rear Control Unit (RCU) module is being installed. Upload the audio RCU module configuration information to the scan tool. Navigator 2. Remove the floor console cupholders. 3. Remove the 2 screws securing the rear trim panel to the floor console. Expedition 4. Remove the 2 screws under the armrest cover. All vehicles 5. Remove the bolt and the center console rear trim panel. - Disengage the pin-type retainers. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Audio Rear Control Unit (RCU) Module > Page 6699 - Disconnect the audio RCU module electrical connector. 6. Remove the RCU module. - Remove the 4 screws. 7. To install, reverse the removal procedure. - Download the configuration information to the audio RCU module. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Audio Rear Control Unit (RCU) Module > Page 6700 Radio/Stereo: Service and Repair Satellite Digital Audio Receiver System (SDARS) Module Satellite Digital Audio Receiver System (SDARS) Module Removal and Installation NOTE: This procedure applies to vehicles without navigation only. For vehicles with navigation, the Satellite Digital Audio Receiver System (SDARS) module is integral to the Audio Control Module (ACM). 1. NOTE: Module configuration is required when a new SDARS module is being installed. Upload the SDARS module configuration information to the scan tool. 2. Remove the center console. 3. Remove the 4 screws and the SDARS module. - Disconnect the electrical connectors. - To install, tighten the screws to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. - Download the configuration information to the SDARS module. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 - Expedition 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 an appropriate tool, pry the steering wheel controls out of the steering wheel. 2. NOTE: Do not allow the electrical connector to fall back into the steering wheel. Remove the steering wheel controls. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise > Page 6712 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise > Page 6718 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6721 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6722 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6723 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6724 Speaker: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6725 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6726 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6727 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6728 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6729 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6730 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6731 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6732 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6733 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Instrument Panel Speaker > Page 6734 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: Front door shown, rear door similar. Removal and Installation All speakers 1. Remove the door trim panels. Front door tweeter speaker 2. Remove the 2 screws and the door tweeter speaker. - Disconnect the electrical connector. Front or rear door speaker 3. Remove the 4 screws and the speaker. - Disconnect the electrical connector. All speakers 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Door > Page 6737 Speaker: Service and Repair Speaker - Subwoofer Speaker - Subwoofer Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the 2 nuts, the bolt, and the subwoofer speaker. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Door > Page 6738 Speaker: Service and Repair Speaker - Instrument Panel Speaker - Instrument Panel Removal and Installation 1. Remove the instrument panel center finish panel. 2. Remove the 4 screws and the instrument panel speaker cover. 3. Remove the 4 screws and the instrument panel speaker. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6744 Accessory Delay Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6745 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations Antenna Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 6749 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 6750 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 6751 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6764 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6765 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6770 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6771 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6781 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6782 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6787 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6788 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 Expedition 2wd Workshop Manual (V8-5.4L (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) Communications Control Module: Locations Accessory Protocol Interface Module (APIM) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6791 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6792 Communications Control Module: Locations Audio Control Module (ACM) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6793 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6794 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6797 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6798 Communications Control Module: Diagrams Audio Control Module (ACM) Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6799 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6800 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6801 Communications Control Module: Diagrams Audio Digital Signal Processing (DSP) Module Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6802 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6803 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6806 - 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6807 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6808 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6809 Communications Control Module: Removal and Replacement Audio Digital Signal Processing (DSP) Module Audio Digital Signal Processing (DSP) Module Audio Digital Signal Processing (DSP) Module Lower Attachment Audio DSP Module Upper Attachment Audio DSP Module Removal Routing Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6810 Removal and Installation 1. NOTE: Module configuration is required when a new audio Digital Signal Processing (DSP) module is being installed. Upload the audio DSP module configuration information to the scan tool. 2. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control Module (ACM) See: Audio Control Module (ACM). 3. Remove the necessary attachments and move the center console 5 cm (2.0 in) towards the rear of the vehicle. 4. Disconnect the audio DSP module electrical connectors. 5. Remove the 2 lower audio DSP module nuts. - To install, tighten to 9 Nm (80 lb-in). 6. NOTICE: The audio Digital Signal Processing (DSP) module is heavy. Be sure to support the amplifier during removal, or damage to the vehicle may occur. Remove the 2 upper audio DSP module nuts. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the audio DSP module. - Route the audio DSP module down and towards the passenger side of the vehicle. 8. To install, reverse the removal procedure. - Download the configuration information to the audio DSP module. Audio Control Module (ACM) Audio Control Module (ACM) NOTE: Expedition without navigation shown, all others similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6811 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 electrical connectors and the antenna cable connector. 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6812 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. 2. Remove the front floor console. 3. Remove the 4 APIM screws and position the APIM aside. 4. Disconnect the Universal Serial Bus (USB) cable and the electrical connectors, and remove the APIM. 5. 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 Removal and Installation 1. Remove the floor console. 2. Remove the rear cupholder trim panel by pulling straight upward to disengage the clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 6813 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6822 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6823 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6828 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6829 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6830 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6831 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6832 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6833 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6834 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6835 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6836 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6837 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6838 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6844 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6845 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6850 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6851 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6852 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6853 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6854 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6855 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6856 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6857 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6858 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6859 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6860 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6865 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6866 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6872 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6873 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) Entertainment System Control Module: Locations Rear Entertainment Module (RETM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 6889 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 6890 Entertainment System Control Module: Locations Audio Rear Control Unit (RCU) Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations > Rear Entertainment Module (RETM) > Page 6891 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) > Page 6894 Entertainment System Control Module: Diagrams Audio Rear Control Unit (RCU) Module Part 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Rear Entertainment Module (RETM) > Page 6895 Part 2 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6904 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6905 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6911 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6912 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6921 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6922 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 6928 ^ 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 Expedition 2wd Workshop Manual (V8-5.4L (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 6929 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6933 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6934 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6935 Parking Assist Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6936 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6937 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6938 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) - Expedition Removal and Installation 1. Disconnect the Parking Aid Module (PAM) sub-harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the sub-harness from the PAM. 5. Remove the 2 PAM bracket bolts. 6. Remove the PAM bracket assembly. 7. Release the module tabs from the bracket and remove the module from the bracket. 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Hood Sensor/Switch (For Alarm): Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6943 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6944 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6949 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6950 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6951 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6952 Parking Assist Distance Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6953 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6954 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6955 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6956 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6957 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6958 Ford Expedition 2wd Workshop Manual (V8-5.4L (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, Front Outer Left > Page 6959 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Outer Left Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Outer Left > Page 6962 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Outer Left > Page 6963 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Outer Left > Page 6964 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Outer Left > Page 6965 Parking Assist Distance Sensor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Outer Left > Page 6966 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Outer Left > Page 6967 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Outer Left > Page 6968 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Parking Aid Sensor - Front Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Front Parking Aid Sensor - Front Sedan Removal and Installation 1. Remove the front bumper cover. 2. Disconnect the parking aid sensor electrical connectors. 3. NOTE: Press the retaining tabs to release the sensor(s). Remove the parking aid sensor(s). 4. To install, reverse the removal procedure. - NOTICE: Paint the new sensor(s) with base coat and one coat of clear. Excessive paint film buildup may result in incorrect sensor operation. Using the scan tool, verify that the parking aid sensor PIDs read no object present, and that the parking aid sensor attenuation PIDs read between 0.8-1.6 ms. If the parking aid sensor attenuation PIDs do not read between 0.8-1.6 ms, the paint is too thick on the sensor(s) and it will be necessary to repaint the sensor(s) as required. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Parking Aid Sensor - Front > Page 6971 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Rear Parking Aid Sensor - Rear Removal and Installation 1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor electrical connectors. 3. NOTE: Press the retaining tabs to release the sensor(s). Remove the parking aid sensor(s). 4. To install, reverse the removal procedure. - Using the scan tool, verify that the parking aid sensor PIDs read no object present, and that the parking aid sensor attenuation PIDs read between 0.8-1.6 ms. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 6975 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 6976 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch Without Memory Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch Without Memory > Page 6979 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch Without Memory > Page 6980 Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch Without Memory > Page 6981 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 6986 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 6987 Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Trailer Connector: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 95-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Trailer Hitch Removal and Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7017 WARNING: Do not permanently remove the trailer hitch. The trailer hitch is an integral part of the vehicle frame. Always reinstall the hitch before delivery of the vehicle to the customer. Failure to follow this instruction may compromise vehicle crash integrity and increase the risk of personal injury in a rear end collision. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the trailer hitch rear bumper cover trim panel, if equipped. 3. Remove the 4 trailer lighting plug cover bolts. 4. Remove the trailer lighting plug. - Position the plug away from the trailer hitch. - Disconnect the electrical connector. - Remove the trailer lighting plug. 5. Remove the electrical connector from the trailer hitch and unclip the harness from the retainers on the frame. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7018 6. Remove the 4 trailer hitch side mounting bolts (2 each side). - To install, tighten to 175 Nm (129 lb-ft). 7. Remove the 4 trailer hitch lower mounting bolts (2 each side) and remove the trailer hitch. - To install, tighten to 275 Nm (203 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7019 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 95-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 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 Expedition 2wd Workshop Manual (V8-5.4L (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 trailer lamps and battery charge are supplied power by relays that are energized to correspond with the exterior lighting functions of the vehicle. If equipped, the vehicle also supplies circuitry to support the installation of an aftermarket Trailer Brake Control (TBC) module (installed by the customer). The vehicle circuitry only supplies voltage, ground, stoplamp switch input and a controlling circuit to the trailer tow connector. The trailer electric brakes themselves are controlled by the aftermarket TBC module and not the vehicle itself. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7046 Visual Inspection Chart 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7047 Trailer Lamps: Symptom Related Diagnostic Procedures Trailer Lamps Symptom Chart Symptom Chart Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7048 Trailer Lamps: Pinpoint Tests Pinpoint Test Y: All The Trailer Lamps Are Inoperative Trailer Lamps Pinpoint Tests Pinpoint Test Y: 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 The trailer tow connectors receive ground through circuit RAT08 (WH) for all of the trailer lamps. The trailer tow parking and stop/turn relays share the same ground through circuit GD123 (BK/GY). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer PINPOINT TEST Y: 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. ------------------------------------------------- Y1 CHECK THE RELAY GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Trailer Tow Parking Lamp Relay. - Measure the voltage between the trailer tow parking lamp relay pin 3, circuit SBB28 (BU/RD), BJB face side and the trailer tow parking lamp relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage greater than 10 volts? Yes GO to Y2. No REPAIR circuit GD123 (BK/GY) for an open. TEST the system for normal operation ------------------------------------------------- Y2 CHECK THE TRAILER TOW CONNECTOR GROUND CIRCUIT FOR AN OPEN THROUGH THE CONNECTOR - Disconnect: Negative Battery Cable. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7049 - For the 4-pin connector, measure the resistance between the trailer tow C4098-4, 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 For the 4-pin connector, REPAIR circuit RAT08 (WH) for an open. TEST the system for normal operation. For the 7-pin connector.GO to Y3. ------------------------------------------------- Y3 CHECK THE TRAILER TOW GROUND CIRCUIT FOR AN OPEN - Disconnect: Trailer Tow C4099. - Measure the resistance between the trailer tow C4099-2, 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 Z: The Individual Trailer Lamp Is Inoperative - Trailer Turn/Stoplamp Trailer Lamps Pinpoint Tests Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - Trailer Turn/Stoplamp Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7050 The Battery Junction Box (BJB) fuse 45 (25A) supplies voltage to both trailer tow turn relays through circuit SBB45 (GY/RD). The trailer tow turn/stop relay coils are provided ground through circuit GD123 (BK/GY). The trailer tow LH turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT09 (GN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow turn relay - Trailer PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - TRAILER TURN/STOPLAMP 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 VERIFY THE TRAILER LAMP OPERATION - Ignition OFF. - Determine if both trailer stop/turn lamps are inoperative. - Are both trailer stop/turn lamps inoperative? Yes VERIFY the BJB fuse 45 (25A) is OK. If OK, REPAIR circuit SBB45 (GY/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. No For an inoperative LH trailer lamp, GO to Z2. For an inoperative RH trailer lamp, GO to Z8. ------------------------------------------------- Z2 CHECK FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR (LH TRAILER STOP/TURN LAMP) - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4098-2, 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7051 - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No For the 4-pin connector, GO to Z4. For the 7-pin connector, GO to Z3. ------------------------------------------------- Z3 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (LH STOP/TURN 7-PIN) - Disconnect: Trailer Tow C4099. - While applying the brake pedal, measure the voltage between the trailer tow C4099-1, 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 Z4. ------------------------------------------------- Z4 CHECK THE TRAILER TOW LH STOP/TURN RELAY - Disconnect: Trailer Tow LH Stop/Turn Relay. - Substitute a known good relay. - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4098-2, circuit CAT06 (YE), harness side and ground. - For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4099-1, circuit CAT06 (YE), harness side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7052 - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer tow turn relay. TEST the system for normal operation. No REMOVE the known good relay. GO to Z5. ------------------------------------------------- Z5 CHECK FOR VOLTAGE TO THE LH STOP/TURN LAMP RELAY COIL - While applying the brake pedal, measure the voltage between the trailer tow LH turn relay pin 1, circuit CLS18 (GY/BN), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z6. No REPAIR circuit CLS18 (GY/BN) for an open. TEST the system for normal operation. ------------------------------------------------- Z6 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE LH STOP/TURN LAMP RELAY - Measure the voltage between the trailer tow LH turn relay pin 3, circuit SBB45 (GY/RD), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z7. No REPAIR circuit SBB45 (GY/RD) for an open. TEST the system for normal operation. ------------------------------------------------- Z7 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE LH STOP/TURN LAMP RELAY USING THE RELAY GROUND PIN - Measure the voltage between the trailer tow LH turn relay pin 3, circuit SBB45 (GY/RD), BJB face side and the trailer tow LH turn relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage greater than 10 volts? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7053 Yes REPAIR circuit CAT06 (YE) for an open. TEST the system for normal operation. No REPAIR circuit GD123 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------- Z8 CHECK FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR (RH TRAILER STOP/TURN LAMP) - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4098-1, 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. No For the 4-pin connector, GO to Z10. For the 7-pin connector, GO to Z9. ------------------------------------------------- Z9 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (RH STOP/TURN 7-PIN) - Disconnect: Trailer Tow C4099. - While applying the brake pedal, measure the voltage between the trailer tow C4099-4, 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 Z10. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7054 ------------------------------------------------- Z10 CHECK THE TRAILER TOW RH STOP/TURN RELAY - Disconnect: Trailer Tow RH Stop/Turn Relay. - Substitute a known good relay. - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4098-1, circuit CAT09 (GN), harness side and ground. - For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4099-4, circuit CAT09 (GN), harness side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer tow turn relay. TEST the system for normal operation. No REMOVE the known good relay. GO to Z11. ------------------------------------------------- Z11 CHECK FOR VOLTAGE TO THE RH STOP/TURN LAMP RELAY COIL - While applying the brake pedal, measure the voltage between the trailer tow RH turn relay pin 1, circuit CLS19 (VT/OG), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z12. No REPAIR circuit CLS19 (VT/OG) for an open. TEST the system for normal operation. ------------------------------------------------- Z12 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE RH STOP/TURN LAMP RELAY - Measure the voltage between the trailer tow RH turn relay pin 3, circuit SBB45 (GY/RD), BJB face side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7055 - Is the voltage greater than 10 volts? Yes GO to Z13. No REPAIR circuit SBB45 (GY/RD) for an open. TEST the system for normal operation. ------------------------------------------------- Z13 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE RH STOP/TURN LAMP RELAY USING THE RELAY GROUND PIN - Measure the voltage between the trailer tow RH turn relay pin 3, circuit SBB45 (GY/RD), BJB face side and the trailer tow RH turn relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage less than 5 ohms? Yes REPAIR circuit CAT09 (GN) for an open. TEST the system for normal operation. No REPAIR ground GD123 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps Trailer Lamps Pinpoint Tests Pinpoint Test AA: The Trailer Lamps Are Inoperative - Trailer 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 The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. The trailer tow parking lamp relay coil is provided ground through circuit GD123 (BK/GY). Voltage is supplied from Battery Junction Box (BJB) fuse 28 (25A) to the trailer tow parking lamp relay switch side through circuit SBB28 (GN/RD). When the trailer tow parking lamp relay is energized, voltage is routed to the trailer tow connector through circuit CAT11 (BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow parking lamp relay - Trailer PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7056 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 FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR - Ignition OFF. - Place the headlamp switch in the PARKING LAMPS ON position. - For the 4-pin connector, measure the voltage between the trailer tow C4098-3, circuit CAT11 (BN), harness side and ground. - For the 7-pin connector, measure the voltage between the trailer tow connector pin 6, circuit CAT11 (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 For the 4-pin connector, GO to AA3. For the 7-pin connector, GO to AA2. ------------------------------------------------- AA2 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (7-PIN) - Disconnect: Trailer Tow C4099. - Measure the voltage between the trailer tow C4099-6, circuit CAT11 (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 AA3. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7057 AA3 CHECK THE TRAILER TOW PARKING LAMP RELAY - Place the headlamp switch in the OFF position. - Disconnect: Trailer Tow Parking Lamp Relay. - Substitute a known good relay. - Place the headlamp switch in the PARKING LAMPS ON position. - For the 4-pin connector, measure the voltage between the trailer tow C4098-3, circuit CAT11 (BN), harness side and ground. - For the 7-pin connector, measure the voltage between the trailer tow C4099-6, circuit CAT11 (BN), harness side and ground. - Is the trailer tow parking lamp relay OK? Yes REMOVE the known good relay. GO to AA4. No REMOVE the known good relay. INSTALL a new trailer tow parking lamp relay. TEST the system for normal operation. ------------------------------------------------- AA4 CHECK FOR VOLTAGE TO THE TRAILER TOW PARKING LAMP RELAY COIL - Measure the voltage between the trailer tow parking lamp relay pin 1, circuit CLS30 (VT/WH), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AA5. No REPAIR circuit CLS30 (VT/WH) for an open. TEST the system for normal operation. ------------------------------------------------- AA5 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE TRAILER TOW PARKING LAMP RELAY - Place the headlamp switch in the OFF position. - Measure the voltage between the trailer tow parking lamp relay pin 3, circuit SBB28 (GN/RD), BJB face side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7058 - Is the voltage greater than 10 volts? Yes GO to AA6. No VERIFY the BJB fuse 28 (25A) is OK. If OK, REPAIR circuit SBB28 (GN/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AA6 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE TRAILER TOW PARKING LAMP RELAY USING THE RELAY GROUND PIN - Measure the voltage between the trailer tow parking lamp relay pin 3, circuit SBB28 (GN/RD), BJB face side and the trailer tow parking lamp relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage greater than 10 volts? Yes REPAIR circuit CAT11 (BN) for an open. TEST the system for normal operation. No REPAIR circuit GD123 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AB: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps Trailer Lamps Pinpoint Tests Pinpoint Test AB: The Trailer Lamps Are Inoperative - Trailer 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 The Battery Junction Box (BJB) fuse 58 (15A) receives voltage from circuit CLS10 (GY/BN) when the vehicle reversing lamps are illuminated. The voltage is then routed to the trailer tow connector through circuit CAT16 (GY/BN). This pinpoint test is intended to diagnose the following: - Fuse Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7059 - Wiring, terminals or connectors - Trailer PINPOINT TEST AB: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING 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. ------------------------------------------------- AB1 CHECK FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR - Ignition OFF. - 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 BJB fuse 58 (15A) is OK. If OK, GO to AB2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AB2 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow C4099. - Measure the voltage between the trailer tow C4099-7, 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 AB3. ------------------------------------------------- AB3 CHECK FOR VOLTAGE TO THE BJB FUSE 58 (15A) - Measure the voltage between the BJB fuse 58 (15A), circuit CLS10 (GY/BN), input side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7060 - Is the voltage greater than 10 volts? Yes REPAIR circuit CAT16 (GY/BN) for an open. TEST the system for normal operation. No REPAIR circuit CLS10 (GY/BN) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AC: The Trailer Lamps Are On Continuously Trailer Lamps Pinpoint Tests Pinpoint Test AC: 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 - Trailer Tow Turn/Stoplamp The trailer tow LH turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT09 (GN). Trailer Tow Parking The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. When the trailer tow parking lamp relay is energized, the voltage is routed to the trailer tow connector through circuit CAT11 (BN). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow relay - Trailer PINPOINT TEST AC: 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. ------------------------------------------------- AC1 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR - Ignition ON. - Measure the voltage between the trailer tow 4-pin connector, harness side and ground as follows: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7061 - Is any voltage present? Yes GO to AC2. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AC2 CHECK THE TRAILER TOW RELAY - Ignition OFF. - Disconnect: Suspect Trailer Tow Relay. - Measure the voltage between the trailer tow 4-pin connector, harness side and ground as follows: - Is any voltage present? Yes REPAIR circuit CAT06 (YE) (LH turn), circuit CAT09 (OG) (RH turn), or circuit CAT11 (BN) (parking lamps) for a short to voltage. TEST the system for normal operation. No INSTALL a new turn trailer tow relay. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AD: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly Trailer Lamps Pinpoint Tests Pinpoint Test AD: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly Normal Operation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7062 The trailer battery charge relay coil receives voltage from the Smart Junction Box (SJB) fuse 42 (10A) through circuit CAT23 (GY/YE) when the ignition switch is in the RUN position. Ground for the trailer battery charge relay coil is supplied through circuit GD123 (BK/GY). The Battery Junction Box (BJB) fuse 21 (30A) supplies voltage to the trailer battery charge relay switch side through circuit SBB21 (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 - SJB PINPOINT TEST AD: 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. ------------------------------------------------- AD1 CHECK FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR (BATTERY CHARGE INOPERATIVE) - 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 AD8. No GO to AD2. ------------------------------------------------- AD2 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR (BATTERY CHARGE INOPERATIVE) - Ignition OFF. - Disconnect: Trailer Tow C4099. - Ignition ON. - Measure the voltage between the trailer tow C4099-5, 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7063 No GO to AD3. ------------------------------------------------- AD3 CHECK THE TRAILER BATTERY CHARGE RELAY (INOPERATIVE) - Ignition OFF. - Disconnect: Trailer Battery Charge Relay. - Substitute a known good relay. - Ignition ON. - Measure the voltage between the trailer tow C4099-5, circuit CAT14 (OG) 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. GO to AD4. ------------------------------------------------- AD4 CHECK FOR VOLTAGE TO THE TRAILER TOW BATTERY CHARGE RELAY - Ignition OFF. - Measure the voltage between the trailer battery charge relay pin 3, circuit SBB21 (GY/RD), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AD5. No VERIFY the BJB fuse 21 (30A) is OK. If OK, REPAIR circuit SBB21 (GY/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AD5 CHECK FOR VOLTAGE TO THE TRAILER TOW BATTERY CHARGE RELAY USING THE RELAY GROUND PIN - Measure the voltage between the trailer battery charge relay pin 3, circuit SBB21 (GY/RD), BJB face side and the trailer battery charge relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage greater than 10 volts? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7064 Yes GO to AD6. No REPAIR circuit GD123 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------- AD6 CHECK FOR VOLTAGE TO THE TRAILER BATTERY CHARGE RELAY COIL (INOPERATIVE CONDITION) - Ignition ON. - Measure the voltage between the trailer battery charge relay pin 1, circuit CAT23 (GN/YE), BJB face side and ground. - Is the voltage greater than 10 volts? Yes REPAIR circuit CAT14 (OG) for an open. TEST the system for normal operation. No VERIFY the SJB fuse 44 (10A) is OK. If OK, GO to AD7. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AD7 CHECK THE TRAILER BATTERY CHARGE RELAY COIL VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: SJB C2280b. - Measure the resistance between the trailer battery charge relay pin 1, circuit CAT23 (GN/YE), BJB face side and the SJB C2280b-6, circuit CAT23 (GN/YE), harness side. - Is the resistance less than 5 ohms? Yes GO to AD12. No REPAIR circuit CAT23 (GN/YE) for an open. TEST the system for normal operation. ------------------------------------------------- AD8 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7065 - Is any voltage present? Yes GO to AD9. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AD9 CHECK THE TRAILER BATTERY CHARGE VOLTAGE SUPPLY CIRCUIT 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. - Is any voltage present? Yes REPAIR circuit CAT14 (OG) for a short to voltage. TEST the system for normal operation. No GO to AD10. ------------------------------------------------- AD10 CHECK FOR VOLTAGE TO THE TRAILER BATTERY CHARGE RELAY COIL (BATTERY CHARGE ALWAYS ON) - Measure the voltage between the trailer battery charge relay pin 1, circuit CAT23 (GN/YE), BJB face side and ground. - Is any voltage present? Yes GO to AD11. No INSTALL a new trailer battery charge relay. TEST the system for normal operation. ------------------------------------------------- AD11 CHECK THE TRAILER BATTERY CHARGE RELAY COIL SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7066 - Disconnect: SJB C2280b. - Measure the voltage between the trailer battery charge relay pin 1, circuit CAT23 (GN/YE), BJB face side and ground. - Is any voltage present? Yes REPAIR circuit CAT23 (GN/YE) for a short to voltage. TEST the system for normal operation. No GO to AD12. ------------------------------------------------- AD12 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 AE: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly Trailer Lamps Pinpoint Tests Pinpoint Test AE: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly Normal Operation The Trailer Brake Control (TBC) module is provided voltage at all times by the Battery Junction Box (BJB) fuse 18 (30A) through circuit SBB18 (YE/RD). Ground for the TBC module is provided through circuit GD138 (BK/WH). The TBC module receives voltage from the stoplamp switch through circuit CLS17 (YE/GY) when the brake pedal is applied. When requested, the TBC module sends voltage to the trailer tow connector through circuit CAT19 (BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TBC module - Trailer PINPOINT TEST AE: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7067 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. ------------------------------------------------- AE1 CHECK THE TRAILER ELECTRIC BRAKE CONTROLLER FOR A SHORTED OUTPUT - Ignition ON. - With the brake pedal released, measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side and ground. - Is any voltage present? Yes GO to AE2. No GO to AE3. ------------------------------------------------- AE2 CHECK THE TBC MODULE OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE - Disconnect: TBC Module C2142. - Measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side and ground. - Is any voltage present? Yes REPAIR circuit CAT19 (BU) for a short to voltage. TEST the system for normal operation. No INSTALL a new TBC module. TEST the system for normal operation. ------------------------------------------------- AE3 CHECK THE TBC MODULE OUTPUT - Ignition OFF. - Set the gain on the TBC module to the maximum setting. - While applying the brake pedal, measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7068 - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No GO to AE4. ------------------------------------------------- AE4 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow C4099. - NOTE: Make sure the gain is still set to the maximum setting. - While applying the brake pedal, measure the voltage between the trailer tow C4099-3, 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 AE5. ------------------------------------------------- AE5 CHECK FOR VOLTAGE TO THE TBC MODULE - Disconnect: TBC Module C2142. - Measure the voltage between the TBC module C2142-1, circuit SBB18 (YE/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to AE6. No VERIFY the BJB fuse 18 (30A) is OK. If OK, REPAIR circuit SBB18 (YE/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7069 ------------------------------------------------- AE6 CHECK THE STOPLAMP SWITCH INPUT TO THE TBC MODULE - While applying the brake pedal, measure the voltage between the TBC module C2142-2, circuit CLS17 (YE/GY), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to AE7. No REPAIR circuit CLS17 (YE/GY) for an open. TEST the system for normal operation. ------------------------------------------------- AE7 CHECK FOR VOLTAGE TO THE TBC MODULE USING THE CONNECTOR GROUND PIN - While applying the brake pedal, measure the voltage between the TBC module C2142-2, circuit CLS17 (YE/GY), harness side and the TBC module C2142-6, circuit GD138 (BK/WH), harness side. - Is the voltage greater than 10 volts? Yes GO to AE8. No REPAIR circuit GD138 (BK/WH) for an open. TEST the system for normal operation. ------------------------------------------------- AE8 CHECK THE TBC MODULE OUTPUT CIRCUIT FOR A SHORT TO GROUND - Measure the resistance between the TBC module C2142-3, circuit CAT19 (BU), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to AE9. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7070 No REPAIR circuit CAT19 (BU) fro a short to ground. TEST the system for normal operation. ------------------------------------------------- AE9 CHECK THE TRAILER ELECTRIC BRAKE CONTROLLER OUTPUT CIRCUIT FOR AN OPEN - Connect a fused jumper wire between the TBC module C2142-1, circuit SBB18 (YE/RD), harness side and the TBC module C2142-3, circuit CAT19 (BU), harness side. - Measure the voltage between the trailer tow C4099-3, circuit CAT19 (BU), harness side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the jumper wire. INSTALL a new TBC module. TEST the system for normal operation. No REMOVE the jumper wire. REPAIR circuit CAT19 (BU) for an open. TEST the system for normal operation. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 7075 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 7076 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 7077 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7080 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7081 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7082 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7094 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7095 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7096 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7097 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7098 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7099 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7100 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7101 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Trailer Connector: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 95-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications Body Control Systems: Specifications Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications > Page 7116 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) - SJB Driver Seat Module (DSM) The DSM is located under the driver seat. It controls the memory functions of the driver seat position, the adjustable pedals, and the exterior rear view mirrors. The memory driver seat feature allows the driver to program 2 personalized seat/adjustable pedal/exterior mirrors position that can be recalled using the memory set switches or the Remote Keyless Entry (RKE) transmitter(s) (part of the Integrated Keyhead Transmitter (IKT) key). Refer to Locks for information on the DSM memory settings activation and deactivation. Smart Junction Box (SJB) NOTE: The time out for the battery saver relay and the accessory delay relay (both are controlled by the SJB) is 1 minute if the vehicle has less than 80 km (50 miles). Once the vehicle passes the approximate mileage threshold of 80 km (50 miles), the time out for both relays is 10 minutes, as described by the Owner's Literature. For the accessory delay relay, refer to Windows. The SJB controls the following functions: - Autolamps - Battery saver - Exterior lighting - Interior lighting - Power windows global open/close - Power locks - Remote Keyless Entry (RKE) - Third row power-fold seat - Tire Pressure Monitoring System (TPMS) - Warning chimes and warning lamps Post Crash Alert The post crash alert function is controlled by the SJB. If the Restraints Control Module (RCM) determines an impact of severity enough to deploy air bags has occurred (the air bags may or may not be deployed by the RCM), the RCM will send a message to the Instrument Cluster (IC) over the High Speed Controller Area Network (HS-CAN) that an air bag deployable impact has occurred. The IC sends the message to the SJB over the Medium Speed Controller Area Network (MS-CAN). The SJB activates the post crash alert function by repeatedly cycling the horn on 3 times, then off for 4 seconds, until the battery dies or the function is turned off. The hazard lights will also flash with the horn sounding, but will keep flashing during the horn off cycle. The post crash alert function can be turned off by: - pressing the hazard switch (which may need to be pressed more than once). - pressing the RKE transmitter UNLOCK button. - pressing the RKE transmitter PANIC button. The post crash alert feature acts similar to the perimeter alarm, but the horn cycle is different. The perimeter alarm function cycles the horn on and off, in regular intervals until 2 minutes and 45 seconds have elapsed, the battery dies or the function is turned off. Turning the ignition to the ON position will not deactivate the post crash alert, but will deactivate an activated perimeter alarm. The post crash alert function cannot be configured off. Ford Expedition 2wd Workshop Manual (V8-5.4L (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, go 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 NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The Driver Seat Module (DSM) is on the Medium Speed Controller Area Network (MS-CAN) communication network. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7119 The DSM controls the memory power exterior mirrors. This feature allows the driver to program personalized mirror positions. Once the driver has stored a mirror position, the driver can recall the setting by pressing the corresponding memory switch or by using a programmed Remote Keyless Entry (RKE) transmitter. Refer to Mirrors. The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or the RKE transmitter. Refer to Seats. The memory adjustable pedals and memory power tilt column are also controlled by the DSM. These systems permit the adjustment of the brake, the accelerator pedals and the tilt column by pressing the desired memory set switch or by using a programmed RKE transmitter. The power fold mirrors are also controlled by the DSM. This system permits the mirrors to be folded in or out using the power mirror switch. 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). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7120 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 SJB. 9. If the DTCs retrieved are related to the concern, go to DTC Charts. See: Diagnostic Trouble Code Descriptions/Smart Junction Box (SJB) 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). NOTE: The time out for the battery saver relay and the accessory delay relay (both are controlled by the SJB) is 1 minute if the vehicle has less than 80 km (50 miles). Once the vehicle passes the approximate mileage threshold of 80 km (50 miles), the time out for both relays is 10 minutes, as described by the Owner's Literature. For the accessory delay relay, refer to Windows. The SJB communicates via the Medium Speed Controller Area Network (MS-CAN). The SJB controls the power door lock system. The SJB monitors the door lock/unlock switch inputs from the interior door lock switches. When the SJB receives an unlock/lock command from any door lock control switch, the module activates the door lock actuators. Refer to Locks. The SJB also controls the following remote lock/unlock features: - Remote Keyless Entry (RKE) transmitter lock/unlock - Panic alarm (button is part of the RKE transmitter) - Keyless entry keypad The SJB controls the autolamp subsystem. The autolamp subsystem provides light-sensitive automatic on/off control of the headlamps and parking lamps. The SJB controls the battery saver, delayed accessory function, the horn, and exterior and interior lighting. The SJB controls the Tire Pressure Monitoring System (TPMS). Field-Effect Transistor (FET) Protection The SJB utilizes a Field-Effect Transistor (FET) protective circuit strategy for many of its outputs (for example, the 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 that time of the fault event and a cumulative counter is started. The module resets the FET protection and after a customer demand of the function (switching the component on, battery saver being energized), attempts Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7121 to provide the requested output (voltage or ground). Each time the module detects an excessive load on the protected circuit, the counter advances. When the excessive circuit load occurs 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 established in the module based on each circuits' total protective capability. For example, if the total predefined tolerance level is 600 fault events, the tolerance levels are reached at 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 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 Clear DTC operation on the scan tool as long as the fault itself has been corrected. If any of the circuits are shorted past the third level, then DTCs B106F and B1342 set along with the associated continuous DTC. These DTCs cannot be cleared and the module must be replaced. The SJB FET protected output circuits for the headlamp system are for the LH low beam output and the RH low beam output circuits. Special Tools Used With Diagnostics Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7122 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7123 B103B-B1119 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7124 B111B-B1172 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7125 B11BA:1C-B1253 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7126 B1255-B1328 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7127 B1331-B1600 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7128 B1601-B1727 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7129 B19A1-B1991 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7130 B1A01:01-B19A8 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7131 B1A05:12-B1A89:01 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7132 B1A89:13-B2051 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7133 B208A-B2282 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7134 B236A-B2404 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7135 B2405-B2607 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7136 B272A-B2741 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7137 B287A-B2918 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7138 B2A2A-B2999 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7139 B2A3A-B2A44 / C1001:01-C1155 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7140 C1165-C1705 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7141 C1706-C1790 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7142 C1795-C2208 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7143 C2209-C2784 / P062F-P0667 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7144 P0701-P0783 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7145 P0784-P1812 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7146 PXXXX-P2764 / U0001-U0073 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7147 U0073-U0140 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7148 U0140-U0155:00 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7149 U0159-U0196:00 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7150 U0197-U0301 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7151 U201A:51-U2023 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7152 U2023-U2101:00 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7153 U261A-U3003:17 Driver Seat Module (DSM) Driver Seat Module (DSM) DTC Charts Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7154 B106E-B1342 / U0140-U0155 Smart Junction Box (SJB) Smart Junction Box (SJB) DTC Charts Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7155 B2A2B-B2949 / P062F / U0155-U2050 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7156 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7157 Body Control Systems: Pinpoint Tests Pinpoint Test F: DTCs B106E, B106F Driver Seat Module (DSM) Pinpoint Tests Pinpoint Test F: DTCs B106E, B106F Normal Operation The Driver Seat Module (DSM) controls the output of several vehicle systems by means of solid state drivers. When an overload occurs on any of these drivers, a DTC will be set. The module also tracks the number of repetitive faults on each of these circuits. The module compares this number of overloads to 3 progressive thresholds established for each circuit. If the 3 thresholds have not been exceeded, then the DTC of the affected circuit can be cleared by eliminating the fault, then clearing the DTCs and running the self-test. At the point that each of the first 2 thresholds are exceeded, B106E will be set along with the DTC relating to the affected circuit. Once the final threshold has been exceeded, the affected output is permanently disabled, and B106F will be set along with B1342, at which time the DSM must be replaced. - DTC B106E (Solid State Driver Disabled Due To Short Circuit) - sets when the DSM has disabled a circuit due to a repetitive fault causing a circuit overload. A corresponding DTC for the circuit in question will also set. - 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 B1342. When DTC B106F is present, a new DSM must be installed after the fault condition has been corrected. This pinpoint test is intended to diagnose the following: - Output circuit short to ground or voltage - DSM PINPOINT TEST F: DTCs B106E, B106F NOTICE: If DTC B106F is present, the fault condition must be corrected prior to installing a new DSM. Failure to correct the fault condition first may cause damage to the new DSM, resulting in a repeat repair. ------------------------------------------------- F1 REVIEW THE DTCs - Review the DTCs from the DSM self-test. - Are DTCs B106F and B1342 present? Yes CORRECT the cause of any other DTCs present. When the other DTCs are corrected, 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 GO to F2. ------------------------------------------------- F2 REPAIR OTHER DTCs - Repair the cause of any DTCs present, other than DTC B106E. Refer to the Diagnostic Trouble Code (DTC) Chart See: Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. - Clear the DTCs. - Carry out the DSM self-test. - Is DTC B106E still present? Yes The fault causing the output state to be disabled is still present. REPAIR the cause of the concern. CLEAR the DTCs. REPEAT the self-test. No Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7158 The system is operating correctly at this time. The concern was caused by a fault in one of the output circuits. ------------------------------------------------Pinpoint Test G: DTC B1317 Driver Seat Module (DSM) Pinpoint Tests Pinpoint Test G: 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 SBB45 (GY/RD). - DTC B1317 (Battery Voltage High) - a continuous memory DTC that sets when the DSM detects battery voltage above 15 volts on circuit SBB45 (GY/RD). This pinpoint test is intended to diagnose the following: - Charging system concern - DSM PINPOINT TEST G: DTC B1317 NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump starting events. ------------------------------------------------- G1 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 G2. ------------------------------------------------- G2 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 G3. ------------------------------------------------- G3 RECHECK FOR DTC B1317 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7159 - 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 H: DTC B1318 Driver Seat Module (DSM) Pinpoint Tests Pinpoint Test H: 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 SBB45 (GY/RD). - DTC B1318 (Battery Voltage Low) - a continuous memory DTC that sets when the DSM detects battery voltage below 10 volts on circuit SBB45 (GY/RD). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - High circuit resistance - DSM PINPOINT TEST H: 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. ------------------------------------------------- H1 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 H2. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7160 ------------------------------------------------- H2 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 H3. ------------------------------------------------- H3 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 H4. No REFER to Charging System. ------------------------------------------------- H4 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-1, circuit SBB45 (GY/RD), harness side and ground. - Is the voltage within 0.2 volt of the recorded battery voltage? Yes GO to H5. No REPAIR the circuit for high resistance. CLEAR the DTC. REPEAT the self-test. ------------------------------------------------- H5 CHECK THE DSM GROUND CIRCUIT - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the DSM C341A-2, circuit GD143 (BK/VT), harness side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7161 - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to H6. No REPAIR the circuit for high resistance. CONNECT the negative battery cable. TEST the system for normal operation. ------------------------------------------------- H6 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 I: DTC U0140 Driver Seat Module (DSM) Pinpoint Tests Pinpoint Test I: DTC U0140 Normal Operation - DTC U0140 (Lost Communication With Body Control Module (GEM)) - set by the DSM whenever it receives invalid data from the Smart Junction Box (SJB). This pinpoint test is intended to diagnose the following: - Module communication - DSM - SJB PINPOINT TEST I: DTC U0140 ------------------------------------------------- I1 VERIFY CUSTOMER CONCERN - Ignition ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7162 - Verify that there is an observable symptom present. - Is an observable symptom present? Yes GO to I2. 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. ------------------------------------------------- I2 CHECK THE COMMUNICATION NETWORK - Ignition ON. - Enter the following diagnostic mode on the scan tool: Network Test. - Carry out the network test. - Does the SJB pass the network test? Yes GO to I3. No REFER to Information Bus. ------------------------------------------------- I3 RETRIEVE THE RECORDED DTCs FROM THE SELF-TEST - Check for recorded DSM DTCs from the self-test. - Is DTC B1317 or B1318 recorded? Yes For DTC B1317, Go To Pinpoint Test g. See: Driver Seat Module (DSM)/Pinpoint Test G: DTC B1317 For DTC B1318, Go To Pinpoint Test h. See: Driver Seat Module (DSM)/Pinpoint Test H: DTC B1318 No GO to I4. ------------------------------------------------- I4 RECHECK THE DSM 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 DSM self-test. - Is DTC U0140 still present? Yes GO to I5. 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. ------------------------------------------------- I5 CHECK FOR DTC U0140 SET IN OTHER MODULES - Clear all DTCs. - Ignition OFF. - Ignition ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7163 - Wait 10 seconds. - Enter the following diagnostic mode on the scan tool: Self-Test. - Retrieve the continuous memory DTCs from all modules. - Is DTC U0140 set in the ACM, DSM, audio DSP module or PAM? Yes INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. No INSTALL a new DSM. REFER to Driver Seat Module (DSM) See: Mirrors/Memory Positioning Systems/Memory Positioning Module/Service and Repair. ------------------------------------------------Pinpoint Test J: DTC U0155 Driver Seat Module (DSM) Pinpoint Tests Pinpoint Test J: DTC U0155 Normal Operation - DTC U0155 (Lost Communication With Instrument Panel Cluster (IC) Control Module) - set by the DSM whenever it receives invalid data from the Instrument Cluster (IC). This pinpoint test is intended to diagnose the following: - Module communication - DSM - IC PINPOINT TEST J: DTC U0155 ------------------------------------------------- J1 VERIFY CUSTOMER CONCERN - Ignition ON. - Verify that there is an observable symptom present. - Is an observable symptom present? Yes GO to J2. 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. ------------------------------------------------- J2 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 J3. No REFER to Information Bus. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7164 ------------------------------------------------- J3 RETRIEVE THE RECORDED DTCs FROM THE SELF-TEST - Check for recorded DSM DTCs from the self-test. Is DTC B1317 or B1318 recorded? Yes For DTC B1317, Go To Pinpoint Test g. See: Driver Seat Module (DSM)/Pinpoint Test G: DTC B1317 For DTC B1318, Go To Pinpoint Test h. See: Driver Seat Module (DSM)/Pinpoint Test H: DTC B1318 No GO to J4. ------------------------------------------------- J4 RECHECK THE DSM 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 DSM self-test. - Is DTC U0155 still present? Yes GO to J5. 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. ------------------------------------------------- J5 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 DSM. REFER to Driver Seat Module (DSM) See: Mirrors/Memory Positioning Systems/Memory Positioning Module/Service and Repair. ------------------------------------------------Pinpoint Test A: DTCs B106E, B106F Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test A: DTCs B106E, B106F Normal Operation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7165 The Smart Junction Box (SJB) controls the output of several vehicle systems by means of solid state drivers. When an overload occurs on any of these drivers, a DTC will be set. The module also tracks the number of repetitive faults on each of these circuits. The module compares this number of overloads to 3 progressive thresholds established for each circuit. If the 3 thresholds have not been exceeded, then the DTC of the affected circuit can be cleared by eliminating the fault, then clearing the DTCs and running the self-test. At the point that each of the first 2 thresholds are exceeded, DTC B106E will be set along with the DTC relating to the affected circuit. Once the final threshold has been exceeded, the affected output is permanently disabled, and DTC B106F will be set along with DTC B1342, at which time the SJB must be replaced. - DTC B106E (Solid State Driver Disabled Due to Short Circuit) - sets when the SJB has disabled a circuit due to a repetitive fault causing a circuit overload. A corresponding DTC for the circuit in question will also set. - 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, a new SJB must be installed after the fault condition has been corrected. 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 a new SJB is to be installed, 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 REVIEW THE DTCs - Review the DTCs from the SJB self-test. Are only DTCs B106E and B106F 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 CORRECT any DTCs present other than DTCs B106E and B106F. REFER to the DTC Charts. After the repair, GO to A2. See: Diagnostic Trouble Code Descriptions/Smart Junction Box (SJB) ------------------------------------------------- A2 CARRY OUT THE SJB SELF-TEST - Carry out the SJB self-test. - Is DTC B106F 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 was caused by a fault in one of the output circuits. ------------------------------------------------Pinpoint Test B: DTCs B2048, B2050, B2949, B2A2B, B2A2C, B2A38 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test B: DTCs B2048, B2050, B2949, B2A2B, B2A2C, B2A38 Normal Operation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7166 If the Smart Junction Box (SJB) is not configured correctly, these DTCs may appear in error. The SJB will need to be configured correctly, which may require entering As-Built data, in order to correct this issue and clear the DTCs. If not, then the following pinpoint test will need to be carried out to determine if the SJB is at fault. - DTC B2048 (Left Rear Turn Lamp Circuit Short to Ground) - sets when the LR turn lamp circuit (on SJB C2280D-21) is shorted to ground. - DTC B2050 (Right Rear Turn Lamp Circuit Short to Ground) - sets when the RR turn lamp circuit (on SJB C2280D-19) is shorted to ground. - DTC B2949 (Global Opening/Closing Circuit Short to Battery) - sets when the global opening/closing circuit (on SJB C2280D-10) is shorted to battery. - DTC B2A2B (Left Corner Lamp Output Circuit Short to Ground) - sets when the left corner lamp output circuit (on SJB C2280B-17) is shorted to ground. - DTC B2A2C (Right Corner Lamp Output Circuit Short to Ground) - sets when the right corner lamp output circuit (on SJB C2280B-19) is shorted to ground. - DTC B2A38 (Floor Lamp Output Circuit Short to Ground) - sets when the floor lamp output circuit (on SJB C2280G-2) is shorted to ground. NOTE: The pins mentioned above are not populated. This pinpoint test is intended to diagnose the following: - SJB PINPOINT TEST B: DTCs B2048, B2050, B2949, B2A2B, B2A2C, B2A38 ------------------------------------------------- B1 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. - Enter the following diagnostic mode on the scan tool: Clear the DTCs. - Enter the following diagnostic mode on the scan tool: Repeat the Self-Test. - Is DTC B2048, B2050, B2949, B2A2B, B2A2C, or B2A38 retrieved (or any combination of the previously mentioned DTCs)? Yes INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. CLEAR the DTCs. REPEAT the self-test. 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. TEST the system for normal operation. ------------------------------------------------Pinpoint Test C: DTC B1317 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test C: 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 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 SDC04 (RD). - DTC B1317 (Battery Voltage High) - a continuous memory DTC that sets when the SJB detects battery voltage above 15 volts on circuit SDC04 (RD). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7167 This pinpoint test is intended to diagnose the following: - Charging system concern - SJB PINPOINT TEST C: DTC B1317 NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump starting events. ------------------------------------------------- C1 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 C2. ------------------------------------------------- C2 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 C3. ------------------------------------------------- C3 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. 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 D: DTC B1318 Smart Junction Box (SJB) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7168 Pinpoint Tests Pinpoint Test D: 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 SDC04 (RD). - DTC B1318 (Battery Voltage Low) - a continuous memory DTC that sets when the SJB detects battery voltage below 10 volts on circuit SDC04 (RD). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - High circuit resistance - SJB PINPOINT TEST D: 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. ------------------------------------------------- D1 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 D2. 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. ------------------------------------------------- D2 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 D3. ------------------------------------------------- D3 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7169 - Is the battery OK and fully charged? Yes GO to D4. No REFER to Charging System. ------------------------------------------------- D4 CHECK THE SJB VOLTAGE SUPPLY - Measure and record the voltage at the battery. - Disconnect: SJB C2280C. - Ignition ON. - Measure the voltage between the SJB C2280C-1, circuit SDC04 (RD), harness side and ground. - Is the voltage within 0.2 volt of the recorded battery voltage? Yes GO to D5. No REPAIR the circuit for high resistance. CLEAR the DTC. REPEAT the self-test. ------------------------------------------------- D5 CHECK THE SJB GROUND CIRCUIT - Ignition OFF. - Disconnect: Negative Battery Cable. - Disconnect: SJB C2280E. - Measure the resistance between the SJB C2280E-7, 8, 12, 24, circuit GD138 (BK/WH), harness side and ground. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to D6. No REPAIR the circuit for high resistance. CONNECT the negative battery cable. TEST the system for normal operation. ------------------------------------------------- D6 CHECK FOR CORRECT SJB OPERATION - Disconnect the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7170 - 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 E: DTC U0155 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test E: 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 E: DTC U0155 ------------------------------------------------- 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 an 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 IC pass the network test? Yes GO to E3. No REFER to Information Bus. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7171 ------------------------------------------------- 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 c. See: Smart Junction Box (SJB)/Pinpoint Test C: DTC B1317 For DTC B1318, Go To Pinpoint Test d. See: Smart Junction Box (SJB)/Pinpoint Test D: DTC B1318 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 U0155 still present? Yes GO to E5. 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. ------------------------------------------------- E5 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations Auxiliary Step / Running Board Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7176 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7177 Auxiliary Step / Running Board Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7178 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7179 Auxiliary Step / Running Board Module: Service and Repair Power Running Board (PRB) Module Removal and Installation 1. Remove the LH B-pillar trim panel. 2. Disconnect the Power Running Board (PRB) module electrical connectors. 3. Remove the 2 bolts and the PRB module assembly. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left Auxiliary Step / Running Board Motor: Locations Running Board Motor, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left > Page 7184 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left > Page 7185 Auxiliary Step / Running Board Motor: Locations Running Board Motor, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left > Page 7186 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left > Page 7189 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 7196 Front Bumper Cover / Fascia: Removal and Replacement Bumper Cover - Front Removal and Installation 1. Remove the 3 lower air deflector pin-type retainers. - Position the air deflector aside. 2. Remove the 2 front bumper cover lower pin-type retainers. 3. Remove the 4 LH and RH front fender splash shield screws. 4. Remove the 4 LH and RH front bumper cover-to-fender bolts. - To install, tighten to 11 Nm (97 lb-in). 5. If equipped, disconnect the fog lamp electrical connector. 6. If equipped, disconnect the park aid sensor electrical connector. 7. Remove the upper air deflector. - Remove the 10 pin-type retainers. NOTE: Right side shown, left side similar. 8. Remove the 2 upper pin-type retainers for the lower air deflector. 9. Remove the 4 grille-to-radiator support bolts. 10. Remove the front bumper cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 7197 11. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 7203 Rear Bumper Cover / Fascia: Removal and Replacement Bumper Cover - Rear Removal and Installation 1. Remove the 4 LH and RH rear fender splash shield screws. NOTE: Left side shown, right side similar. 2. Remove the 4 LH and RH inner bumper cover nuts. 3. If equipped, disconnect the reverse parking aid electrical connector. 4. Remove the 2 rear bumper cover lower pin-type retainers. 5. Remove the rear bumper cover. - Remove the 2 rear bumper cover pin-type retainers and the 3 rear bumper cover bolts. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Removal and Installation Both sides 1. Remove the windshield wipers. LH side 2. Remove the pin-type retainer and lift the LH cowl trim panel to release the 3 underside pushpin retainers that are attached to the cowl trim panel. - Disconnect the windshield washer tube. RH side 3. Remove the pin-type retainer and lift the RH cowl trim panel to release the 2 underside pushpin retainers that are attached to the cowl trim panel. - Disconnect the windshield washer tube. Both sides 4. To install, reverse the removal procedure. 5. If necessary, adjust the windshield wiper arms. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Front Door Exterior Handle: Service and Repair Exterior Front Door Handle Removal and Installation NOTE: The front door window glass must be completely raised. 1. Remove the front door trim panel. - Position the water shield aside. 2. Open the clip and disconnect the exterior door handle actuating rod. 3. If equipped, disconnect the door lock cylinder actuating rod from the lock cylinder. 4. NOTE: Push the exterior door handle out from the bottom surface of the handle. Remove the 2 nuts and the exterior front door handle. - To install, tighten to 9 Nm (80 lb-in). 5. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a relaxed position and that the exterior door handle rod is all the way up before closing the clip. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 > Page 7215 To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Interior Handle: Service and Repair Interior Door Handle NOTE: Door trim panel removed for clarity. Removal and Installation 1. Remove the screw and the interior door handle trim bezel. 2. Release the door handle retaining clip and position the interior door handle aside. 3. Release the interior door handle actuating cable from the interior door handle. 4. NOTE: Make sure the interior door handle spring is realigned before installation of the door handle. Check for normal operation. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 All alignments 1. NOTE: Driver side shown, passenger side similar. Remove the door latch striker plate. Front door in and out, up and down alignment 2. Loosen, but do not remove, the front door hinge-to-front door fasteners enough to allow door alignment. Front door fore, aft and tilt alignment 3. Remove the front fender. 4. Loosen, but do not remove, the upper front door hinge-to-body fasteners enough to allow door alignment. 5. Loosen, but do not remove, the lower front door hinge-to-body fasteners enough to allow door alignment. All alignments 6. Adjust the door. 7. 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). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7222 8. Install and adjust the door striker as necessary. - Tighten the door latch striker plate bolts to 25 Nm (18 lb-ft). 9. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Procedures > Page 7228 Front Door Latch: Removal and Replacement Front Door Latch Removal and Installation NOTE: The door glass must be completely raised. 1. Remove the front door trim panel. - Position the watershield aside. 2. For the LH door, disconnect the door lock cylinder actuating lock rod from the lock cylinder. 3. Open the clip and disconnect the exterior door handle actuating rod. 4. Disconnect the manual actuating lock rod from the door latch. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Procedures > Page 7229 5. Remove and discard the 3 bolts and position the front door latch aside. - To install, tighten to 12 Nm (106 lb-in). 6. Disconnect the electrical connectors. - Separate the door harness from the door latch. 7. Release the interior door handle actuating cable and remove the front door latch. 1. Position the cable cover aside. 2. Release the conduit and the interior door handle actuating cable. 8. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a neutral position and that the exterior door handle rod is all the way up before closing the clip. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair Door Check Arm Left and right sides 1. Remove the lower cowl trim panel. - Remove the door scuff plate. Left side 2. Remove the parking brake control assembly and position aside. Left and right sides 3. Remove the lower cowl panel weather shield. 4. Remove the 2 door check arm-to-door bolts. 5. NOTE: Left side shown, right side similar. Remove the 2 door check arm nuts. 6. Remove the door check arm from the opening in the lower cowl panel. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Expedition shown, Navigator, Expedition EL and Navigator L similar. Removal and Installation NOTE: Left front door shown, right front door similar. 1. Remove the door handle screw cover. - Use the service notch. 2. Remove the door handle screw. 3. Remove the door handle trim bezel. 4. Remove the front door trim panel finish cover. 5. Remove the 2 door trim panel armrest screws. 6. Remove the door trim panel screw. 7. Remove the 2 lower door trim panel screws. 8. Disengage the sail panel clip. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 7236 9. NOTICE: To avoid damage to the door trim panel, lift the door trim panel by pulling directly upward on the armrest to disengage the panel clips. Remove the front door trim panel. - Disconnect the electrical connectors. 10. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7242 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation NOTE: The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Windows and Glass/Windows/Service and Repair. 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 inside glass weatherstrip. 3. Remove the front door glass channel bolt and front door glass top run. - To install, tighten to 11 Nm (97 lb-in). 4. To install, reverse the removal procedure. - The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Windows and Glass/Windows/Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7247 Front Door Window Motor: Service and Repair Window Regulator Motor - Front Door Window Regulator Motor - Front Door Removal and Installation NOTE: The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Windows and Glass/Windows/Service and Repair. 1. Remove the front door trim panel. 2. Position the front door weathershield aside. 3. NOTE: Use a flat-blade screwdriver between the window regulator motor and window regulator assembly to hold the window regulator assembly drum in place. Remove the bolts and the front door window regulator motor. 1. Disconnect the electrical connector. 2. Remove the bolts. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. - Cycle the window glass to make sure the gears engage. - The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) window regulator is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Windows and Glass/Windows/Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7252 Front Door Window Regulator: Service and Repair Window Regulator - Front Door Window Regulator - Front Door Removal and Installation NOTE: The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Windows and Glass/Windows/Service and Repair. 1. Remove the front door trim panel. 2. NOTE: There are 2 tabs on the opposite side not shown in the illustration. Unlock the 4 tabs and remove the window control switch from the door trim panel. 3. Remove the screws and the front door speaker. - Disconnect the electrical connector. 4. Remove the front door weathershield. 5. Re-connect the electrical connectors to the window control switch. 6. Lower the window glass to access the 2 window glass clamp bolts. 7. Loosen the window glass clamp bolts. - To install, raise the window glass until it stalls in the UP position. Tighten the window glass clamp bolts to 11 Nm (97 lb-in). 8. NOTE: Secure the front window glass in the full UP position. Secure the front window glass with tape to the front door frame. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7253 9. Position the interior door handle aside. 1. Remove the cable conduit fitting from the carrier assembly. 2. Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. 3. Remove the cable from the door handle. 10. Release the crash sensor harness pin-type retainers. 11. Position the front door window regulator harness aside. 1. Disconnect the electrical connectors. 2. Release the pin-type retainers. 12. Remove the front window regulator. 1. Loosen the 2 hanger bolts. 2. Remove the front window regulator bolts and front top run channel bolt. - To install, tighten to 11 Nm (97 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7254 13. To install, reverse the removal procedure. - The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) window regulator is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Windows and Glass/Windows/Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Rear Door Exterior Handle: Service and Repair Exterior Rear Door Handle Removal and Installation NOTE: The door glass must be completely raised. 1. Remove the rear door trim panel. - Position the water shield aside. 2. Remove and discard the 3 bolts and position the rear door latch aside. - To install, tighten to 9 Nm (80 lb-in). 3. Open the clip and disconnect the exterior 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. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a relaxed position and that the exterior door handle rod is all the way up before closing the clip. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments Rear Door Hinge: Adjustments Door Alignment - Rear All alignments 1. NOTE: Driver side shown, passenger side similar. Remove the door latch striker plate. Rear door in and out, up and down alignment 2. Loosen, but do not remove, the rear door hinge-to-rear door fasteners enough to allow door alignment. Front door fore, aft and tilt alignment 3. Remove the B-pillar trim panel. 4. Loosen, but do not remove, the rear door hinge-to-body nuts inside at the inside B-pillar enough to allow door alignment. All alignments 5. Adjust the door. 6. Tighten the door fasteners. - 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). 7. Install and adjust the door striker as necessary. - Tighten the door latch striker plate bolts to 25 Nm (18 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Procedures > Page 7268 Rear Door Latch: Removal and Replacement Rear Door Latch Removal and Installation NOTE: The rear door window glass must be completely raised. 1. Remove rear door trim panel. - Position the watershield aside. 2. Remove and discard the 3 bolts and position the rear door latch aside. - To install, tighten to 12 Nm (106 lb-in). 3. Open the clip and disconnect the exterior door handle actuating rod. 4. Disconnect the electrical connectors. 5. Release the interior door handle actuating cable and remove the rear door latch. 1. Position the cable cover aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Procedures > Page 7269 2. Release the conduit and the interior door handle actuating cable. 6. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a neutral position and that the exterior door handle rod is all the way up before closing the clip. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Expedition shown, Navigator, Expedition EL and Navigator L similar. Removal and Installation NOTE: Left rear door shown, right rear door similar. 1. Remove the door handle screw cover. - Use the service notch. 2. Remove the door handle screw. 3. Remove the door handle trim bezel. 4. Remove the rear door trim panel finish cover. 5. Remove the 2 door trim panel armrest screws. 6. Remove the door trim panel screw. 7. Remove the 2 lower door trim panel screws. 8. NOTICE: To avoid damage to the door trim panel, lift the door trim panel by pulling directly upward on the armrest to disengage the panel clips. Remove the rear door trim panel. - If equipped, disconnect the electrical connectors. 9. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 rear door glass channel bolt. - To install, tighten to 11 Nm (97 lb-in). 3. Remove the rear door glass top run. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7278 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7283 Rear Door Window Motor: Service and Repair Window Regulator Motor - Rear Door Window Regulator Motor - Rear Door Removal and Installation 1. Remove the rear door trim panel. 2. Position the rear door weathershield aside. 3. NOTE: Use a flat-blade screwdriver between the window regulator motor and the window regulator assembly to hold the window regulator assembly drum in place. Remove the rear door window regulator motor. 1. Disconnect the electrical connector. 2. Remove the bolts. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. - Cycle the door glass to make sure of gear engagement. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7288 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. NOTE: There are 2 tabs on the opposite side not shown in the illustration. NOTE: LF shown, LR and RR are similar. Unlock the 4 tabs and remove the window control switch from the door trim panel. 3. Remove the rear door speaker. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the speaker. 4. Remove the rear door weathershield. 5. Connect the window control switch. 6. Lower the window glass to access the window glass clamp bolts. 7. Disconnect the window control switch. 8. Loosen the window glass clamp bolts and remove the rear door window glass. - To install, tighten to 11 Nm (97 lb-in). 9. NOTE: Secure the rear window glass in the full UP position. Secure the rear window glass with tape to the rear door frame. 10. Disconnect the rear door window regulator electrical connectors. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7289 11. Position the interior door handle aside. - Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. 12. Remove the rear door window regulator assembly. - Remove the bolts. - To install, tighten to 11 Nm (97 lb-in). 13. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTICE: The fuel filler door cup bezel is a one-time use only part. Removal of this part will result in damage to the component. NOTICE: Do not attempt to pry on the bottom of the fuel filler door cup bezel. Failure to follow this direction may result in damage to the vehicle. 1. Using a non-marring body tool, pry outward on the upper RH side of the fuel filler door cup bezel until the clip breaks. 2. Using a non-marring body tool, pry the upper LH side of the fuel filler door cup bezel until the clip breaks. 3. Pull upward and outward to remove the fuel filler door cup bezel. Installation 1. NOTICE: Make sure to align the fuel filler door cup bezel to the alignment slots and the filler neck. Failure to follow this direction may result in damage to the component and/or vehicle. Align the fuel filler door cup bezel to the vehicle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Page 7293 2. Push inward and downward until the clips snap into place. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair Hood Latch NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Remove the 10 pin-type retainers and the upper radiator sight shield. 2. Remove the 2 bolts and the hood latch. - To install, tighten to 35 Nm (26 lb-ft). 3. Release the hood latch cable from the hood latch. 4. To install, reverse the removal procedure. - Verify the hood latch engages the striker in the latched position (secondary). - Verify the hood latch engages the striker in the fully latched position (primary). - Adjust the hood latch as necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair Hood Latch Release Handle NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Remove the hood latch. For additional information, refer to Hood Latch See: Hood Latch/Service and Repair. - Note the routing of the hood release cable. 2. Remove the 3 screws and the steering column cover. 3. Remove the 2 screws and the hood latch release handle. 4. Release the cable guides and pull the cable through the cowl panel. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Hood Sensor/Switch (For Alarm): Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7305 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7306 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Window glass assembly 1. Remove the rear window wiper motor. 2. Disconnect the rear window defrost electrical connectors. 3. NOTICE: Do not extend the socket clips more than 2.0 mm (0.08 in) or failure of the socket can occur. NOTE: The liftgate glass must be supported when removing and installing the liftgate assist cylinders. Disconnect the 2 liftgate glass assist cylinders. 1. Insert a screwdriver blade under the socket clip and lift. 2. Gently pull the socket off the ball stud. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 7311 Window glass assembly or hinge assembly 4. Remove the liftgate glass hinge-to-body fasteners and remove the glass. - To install, tighten to 12 Nm (106 lb-in). Window hinge assembly 5. Remove the liftgate glass to hinge fasteners and remove the glass. - Apply threadlock to the liftgate glass-to-hinge fasteners during installation. - To install, tighten to 8 Nm (71 lb-in). Window glass assembly or window hinge assembly 6. To install, reverse the removal procedure. - Check the liftgate glass for high effort when closing. If high effort is present, adjust the striker one-half turn outboard. If high effort is still present, adjust the striker an additional one-half turn outboard. Do not exceed one full turn. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations Power Trunk / Liftgate Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 7315 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 7316 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 7317 Power Trunk / Liftgate Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 7318 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Liftgate Latch Remote Control Power Trunk / Liftgate Control Module: Service and Repair Liftgate Latch Remote Control Liftgate Latch Remote Control Removal and Installation NOTE: The liftgate latch remote control is available with power liftgate only. 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. NOTICE: Be careful not to kink the liftgate latch actuating cable while disconnecting it from the latch. Disconnect the liftgate latch. 1. Release the liftgate latch actuator rod. 2. Disconnect the liftgate latch actuating cable. 4. Remove 3 bolts and position the liftgate latch remote control aside. - To install, tighten to 11 Nm (8 lb-in). 5. Disconnect the electrical connectors and remove the liftgate latch remote control. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Liftgate Latch Remote Control > Page 7321 Power Trunk / Liftgate Control Module: Service and Repair Liftgate/Trunk Module (LTM) Liftgate/Trunk Module (LTM) Removal and Installation 1. Remove the rear quarter trim panel. 2. Remove the Liftgate/Trunk Module (LTM). 1. Disconnect the electrical connectors. 2. Remove the bolt. - To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. - Initialize the power liftgate. For additional information, refer to Power Liftgate Initialization See: Service and Repair/Procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Power Trunk / Liftgate Lock Actuator: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 7325 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 7326 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 7327 Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Latch Actuator Removal and Installation 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Release the liftgate latch actuator rod from the liftgate latch. 4. Disconnect the liftgate latch actuator electrical connector. 5. Remove the rivet and the liftgate latch actuator. 6. To install, reverse the removal procedure. - Use the Heavy Duty Riveter to install the new rivet. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch Power Trunk / Liftgate Lock Switch: Locations Handle Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 7332 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 7333 Power Trunk / Liftgate Lock Switch: Locations Liftgate Glass Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 7334 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch Power Trunk / Liftgate Lock Switch: Diagrams Handle Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 7337 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 7338 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 7339 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch Expedition Navigator Removal and Installation All vehicles 1. Remove the liftgate trim panel. - Position the water shield aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 7340 Expedition 2. Remove the 2 nuts and the liftgate release handle. - Disconnect the electrical connector. - To install, tighten to 6 Nm (53 lb-in). 3. Remove the liftgate release switch. - Disconnect the electrical connector. Navigator 4. Remove the liftgate parking lamps. 5. Remove the 6 nuts and the license plate housing. - Disconnect the electrical connector. - To install, tighten to 5 Nm (44 lb-in). 6. Remove the 2 nuts and the liftgate release switch housing. - Disconnect the electrical connector. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the liftgate release switch. - Disconnect the electrical connector. All vehicles 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Liftgate Pinch Strip, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Liftgate Pinch Strip, Left > Page 7345 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Non-power liftgate shown, power liftgate similar. All vehicles 1. Open the liftgate glass and remove the 2 scrivets. Vehicles with power liftgate 2. Remove the power liftgate rod-to-liftgate cover and nut. - To install, tighten to 11 Nm (97 lb-in). 3. Remove the power liftgate rod from the liftgate. All vehicles 4. Remove the upper liftgate trim panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Page 7349 - Pull the lower corners toward the center on both sides and pull down along the top. 5. Remove the liftgate assist handle. 1. Remove the 2 liftgate assist handle screws. 2. Remove the liftgate assist handle. 6. NOTICE: To avoid damage to the liftgate trim panel, remove any retaining clips from the body and attach them to the liftgate trim panel before installing. NOTE: The back of the liftgate trim panel shown, with the location of the liftgate trim panel retainers indicated. Remove the lower liftgate trim panel. - Pull the lower liftgate trim panel at the center to release the center retaining clips. - Release the remaining retaining clips 2 to 3 at a time, starting from the right side and working to the left side. - When all of the retaining clips are released, slide the liftgate trim panel forward and down, away from the liftgate. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Diagrams > Liftgate Latch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Diagrams > Liftgate Latch > Page 7354 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures Trunk / Liftgate Latch: Procedures Liftgate Latch Manual Release 1. Remove the liftgate latch access cover from the center of the liftgate trim panel. 2. Vehicles with manual liftgate, press the liftgate latch manual release lever to the left to release the liftgate latch. 3. Vehicles with power liftgate, press the liftgate latch manual release lever down to release the liftgate latch. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 7357 Trunk / Liftgate Latch: Removal and Replacement Liftgate Latch Liftgate Latch Manual Liftgate Power Liftgate Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 7358 Removal and Installation 1. Remove the liftgate trim panel. - Position the watershield aside. 2. Remove and discard the 3 bolts (4 bolts if equipped with a power liftgate) and the liftgate latch. - Disconnect the electrical connector. - To install, tighten to 12 Nm (106 lb-in). 3. To install, reverse the removal procedure. Liftgate Latch - Window Liftgate Latch - Window Removal and Installation 1. Remove the liftgate trim panel. 2. Remove the 2 screws and the liftgate window latch. - Disconnect the electrical connector. - To install, tighten to 8 Nm (71 lb-in). 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations Trunk / Liftgate Motor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Page 7362 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Page 7363 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Page 7364 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Page 7365 Trunk / Liftgate Motor: Service and Repair Power Liftgate Motor Removal and Installation 1. Remove the power liftgate rod assembly. For additional information, refer to Power Liftgate Rod See: Trunk / Liftgate Shock / Support/Service and Repair. 2. Disconnect the power liftgate motor electrical connectors. 3. Remove the power liftgate retaining fasteners and the power liftgate motor assembly. - To install, tighten to 11 Nm (97 lb-in). 4. To install, reverse the removal procedure. - Initialize the power liftgate. For additional information, refer to Power Liftgate Initialization See: Service and Repair/Procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Position Sensor > Component Information > Service and Repair Trunk / Liftgate Position Sensor: Service and Repair Pinch Strip Switch Removal and Installation NOTE: Left side shown, right side similar. 1. Remove the brake light. - Remove the screws. 2. Disconnect the pinch strip electrical connector. 3. Remove the pinch strip. 1. Remove the pin-type retainers. 2. Remove the grommet and route the harness out of the vehicle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Position Sensor > Component Information > Service and Repair > Page 7369 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair Power Liftgate Rod Removal and Installation 1. Remove the LH quarter trim panel. 2. Unclip the power liftgate rod from the motor assembly. - Squeeze the clip as shown to release and position upward on the rod assembly. 3. Remove the cover and the power liftgate rod-to-liftgate retaining nut. - To install, apply threadlock to the threads of fastener and tighten to 11 Nm (97 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Page 7373 4. Remove the power liftgate rod-to-bracket bolt and the power liftgate rod assembly. - To install, tighten to 30 Nm (22 lb-ft). 5. To install, reverse the removal procedure. - Initialize the power liftgate. For additional information, refer to Power Liftgate Initialization See: Service and Repair/Procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch Trunk / Liftgate Switch: Locations Liftgate Rear Control Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 7378 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 7379 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 7380 Trunk / Liftgate Switch: Locations Power Liftgate/Traction Control/Hazard Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 7381 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch > Page 7384 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Removal and Installation Both sides 1. Remove the windshield wipers. LH side 2. Remove the pin-type retainer and lift the LH cowl trim panel to release the 3 underside pushpin retainers that are attached to the cowl trim panel. - Disconnect the windshield washer tube. RH side 3. Remove the pin-type retainer and lift the RH cowl trim panel to release the 2 underside pushpin retainers that are attached to the cowl trim panel. - Disconnect the windshield washer tube. Both sides 4. To install, reverse the removal procedure. 5. If necessary, adjust the windshield wiper arms. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Vehicles with power running boards 1. Lower the running board. 2. WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions may result in serious personal injury. With the vehicle in NEUTRAL, position it on a hoist. All vehicles 3. Remove the lower pin-type retainer from the fender. 4. Remove the 8 fender splash shield screws. 5. Remove the 2 inner pin-type retainers from the fender splash shield. 6. Remove the fender splash shield. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Fender Splash Shield > Page 7395 Front Fender Liner: Service and Repair Front End Body Panels - Exploded View Front End Body Panels - Exploded View NOTE: Navigator shown, Expedition similar. 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation DESCRIPTION AND OPERATION Frame and Body Mounting The frame is made up of 2 steel boxed side rails and crossmembers, which are welded to the 2 side rails. The transmission crossmember is bolted to the side rails. The side welded rails and crossmembers are not replaced separately. The service kits available for the frame are the following: RH front horn replacement kit - LH front horn replacement kit - Front bumper bracket replacement kit - 1B crossmember replacement kit - Transmission crossmember replacement kit - Exhaust hanger bracket kit Refer to the instructions included in the kits for installation instructions. Frame Mounted Heat Shields All frame-mounted heat shields, except the spare tire heat shield and the upper control arm heat shield, are tightened to 20 Nm (177 lb-in). The spare tire heat shield is tightened to 25 Nm (18 lb-ft). The upper control arm heat shield is tightened to 15 Nm (133 lb-in). Frame Components Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7400 Frame Components Spare Tire Winch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7401 Spare Tire Winch Skid Plates Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7402 Skid Plates NOTICE: When removing upper body mounts, enough adjacent body mount support bolts or nuts must be removed to prevent damage occurring to the vehicle. NOTE: Do not reuse body support mounting fasteners. New fasteners must be installed for each fastener that has been removed or loosened. - No lubricants of any kind are to be used during body mount installation. Body Support - Front End Sheet Metal (FESM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7403 Body Support Front End Sheet Metal (FESM) Body Support - No. 1 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7404 Body Support - No. 1 Body Support - No. 2 and No. 3 NOTE: No. 2 body mount shown, No. 3 body mount similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7405 Body Support - No. 2 and No. 3 Body Support - No. 4 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7406 Body Support - No. 4 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair Transmission Support Crossmember Removal and Installation Transmission Support Crossmember - Exploded View NOTE: Transmission not shown for clarity. Transmission Support Crossmember - Exploded View 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the skid plate fasteners and skid plate. 3. Remove the LH and RH exhaust heat shield-to-crossmember fasteners. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Page 7410 4. Remove the 2 transmission mount nuts. - To install, tighten to 103 Nm (76 lb-ft). 5. Support the transmission. 6. NOTE: - Mark the transmission crossmember next to the edge of the frame bracket to make sure the crossmember is installed in the same position it was removed from. - The crossmember nuts are installed on the crossmember bolts facing the front of the vehicle. Remove the 4 transmission crossmember bolts (2 each side) and the transmission crossmember. To install, tighten to 90 Nm (66 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Page 7411 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Trailer Hitch Removal and Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7415 WARNING: Do not permanently remove the trailer hitch. The trailer hitch is an integral part of the vehicle frame. Always reinstall the hitch before delivery of the vehicle to the customer. Failure to follow this instruction may compromise vehicle crash integrity and increase the risk of personal injury in a rear end collision. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the trailer hitch rear bumper cover trim panel, if equipped. 3. Remove the 4 trailer lighting plug cover bolts. 4. Remove the trailer lighting plug. - Position the plug away from the trailer hitch. - Disconnect the electrical connector. - Remove the trailer lighting plug. 5. Remove the electrical connector from the trailer hitch and unclip the harness from the retainers on the frame. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7416 6. Remove the 4 trailer hitch side mounting bolts (2 each side). - To install, tighten to 175 Nm (129 lb-ft). 7. Remove the 4 trailer hitch lower mounting bolts (2 each side) and remove the trailer hitch. - To install, tighten to 275 Nm (203 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7417 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Grille: Service and Repair Radiator Grille Radiator Grille Expedition Navigator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille > Page 7425 Removal and Installation All vehicles 1. Remove the front bumper cover. Expedition only 2. Remove the 4 bumper assembly-to-grille bracket retainer nuts and the bumper assembly-to-grille bracket. All vehicles 3. NOTE: Expedition shown, Navigator similar. Remove the clips and remove the front grille. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille > Page 7426 Grille: Service and Repair Radiator Grille Support Radiator Grille Support Removal and Installation 1. Remove the front bumper cover. 2. Remove the headlamp bolts. 3. Disconnect the battery. 4. Remove the 4 electrical junction box bolts. - To install, tighten to 35 Nm (26 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille > Page 7427 5. Disconnect the ambient air temperature sensor retaining clip and position the sensor and harness aside. 6. Disconnect the horn assembly electrical connector and remove the horn assemble bracket bolt. - To install, tighten to 35 Nm (26 lb-ft). 7. Disconnect the hood latch cable retainers, remove the hood latch assembly bolts and position the latch assembly and cable aside. - To install, tighten to 35 Nm (26 lb-ft). 8. Remove the LH and RH coolant module bolts. - To install, tighten to 15 Nm (133 lb-in). 9. Remove the 6 radiator grille support bolts (3 each side). - To install, tighten to 35 Nm (26 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille > Page 7428 10. Remove the radiator grille support. 11. NOTICE: Inspect and transfer all of the radiator grille support isolators. Replace as necessary. NOTE: Transfer all necessary components. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Overhead console with roof opening panel shown, all others similar. Removal and Installation 1. Using a suitable trim removal tool, remove the overhead console by prying down on the overhead console to release the 2 retaining clips. 2. Disconnect the electrical connector(s). 3. To install, reverse the removal procedure. - Make sure to align the overhead console retaining clips to the adjacent retaining clip holes. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7435 Console: Service and Repair Console - Front, Floor Console - Front, Floor, Expedition Removal All vehicles 1. Apply the parking brake. 2. Position the selector lever in the NEUTRAL position. 3. Position the front seats forward. 4. Remove the 2 front floor console rear bolts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7436 5. Position the front seats rearward. 6. Remove the 2 front floor console front bolts. - Remove the 2 front floor console bolt covers. - Remove the 2 front floor console bolts. 7. Remove the selector lever trim ring. Funkmaster Flex edition only 8. NOTICE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Using an appropriate pry tool, slightly lift the lower RH corner of the serial numbered name plate upward to gain access to the double-sided adhesive tape, located on the bottom of the name plate. 9. NOTICE: The serial numbered name plate is securely fastened to the console with double-sided adhesive tape. Excessive lifting or prying will bend or damage the serial numbered name plate. Starting at the RH corner of the serial numbered name plate, position a piano wire, or an equivalent tool, between the name plate and the floor console finish panel and cut the double-sided adhesive tape on the bottom of name plate. 10. Remove the serial numbered name plate. All vehicles except Funkmaster Flex edition 11. Remove the front floor console utility tray mat. All vehicles 12. Remove the front floor console utility tray screw. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7437 13. Remove the floor console upper finish panel. 14. Position the selector lever indicator bezel aside. - Release the 4 retainers and position aside. 15. Disconnect the selector lever cable from the selector lever and the floor console. 16. Remove the front floor console front screws. 17. Disconnect the front floor console electrical connectors. 1. Loosen the bulkhead electrical connector bolts. 2. Disconnect the bulkhead electrical connectors. 3. Disconnect the electrical connector. 18. Remove the front floor console. Installation All vehicles Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7438 1. Install the front floor console. 2. Connect the front floor console electrical connectors. - Tighten the bulkhead electrical connector bolt to 3 Nm (27 lb-in). 3. Install the front floor console front screws. - Tighten to 7 Nm (62 lb-in). 4. Install the selector lever cable. 5. Install the selector lever indicator bezel. 6. Install the floor console upper finish panel. - Make sure to align the trim panel retaining clips to the retaining clip holes in the floor console. 7. Install the front floor console utility tray screw. All vehicles except Funkmaster Flex edition 8. Install the front floor console utility tray mat. Funkmaster Flex edition only 9. Using alcohol, remove the double-sided adhesive tape from the serial numbered name plate and floor console finish panel surfaces. 10. Locally obtain 3M PT1100 double-sided adhesive tape and apply 6 new tape strips to the bottom of the serial numbered name plate, as indicated. 11. Position the serial numbered name plate onto the floor console finish panel and apply downward pressure, to securely fasten the name plate to the floor console finish panel. All vehicles 12. Install the selector lever trim ring. 13. Install the 2 front floor console front bolts. - Tighten to 11 Nm (97 lb-in). 14. Install the 2 front floor console front bolt covers. 15. Position the front seats forward. 16. Install the 2 front floor console rear bolts. - Tighten to 11 Nm (97 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7439 17. Position the front seats rearward. 18. Position the selector lever in the PARK position. 19. Release the parking brake Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7440 Console: Service and Repair Console - Rear, Floor Console - Rear, Floor Removal and Installation 1. Remove the 2 rear floor console front bolts. - Open the rear floor console storage bin. - Remove the rear floor console cup holder. - Remove the rear floor console front bolts. To install, tighten to 12 Nm (106 lb-in). 2. Remove the 2 rear floor console rear bolts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7441 - Open the rear floor console storage compartment door. - Remove the rear floor console rear bolts. - Remove the rear floor console. 3. To install, reverse the removal procedure. - Make sure to align the trim panel retaining clips to the retaining clip holes in the floor console. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 switch 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 portion 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. Make sure that all SRS components are connected. 2. Turn the ignition switch from OFF to ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7447 3. Install RCM fuse 32 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will illuminate 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. The flashing might not occur until approximately 30 seconds after the ignition 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 a 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 using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7448 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 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: 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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 portion 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. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column to allow for steering column upper and lower shroud removal. 9. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to the left from the straight-ahead position to access the driver air bag module wire clips and to prevent damage to the steering column multi-function switch. Failure to follow this instruction may result in component damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7449 Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position) as shown. 10. Remove the lower steering column opening cover. - Remove the 3 screws. - Pull out to release the top retainers. - Remove the lower steering column opening cover. If equipped, disconnect the adjustable pedals switch connector. 11. If equipped, remove the screw and steering column manual tilt lever. 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 15. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel. Failure to follow this instruction may result in component damage and/or system failure. NOTE: Steering wheel is removed for clarity. The rear of the steering wheel is shown. NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7450 16. NOTE: Once the driver air bag module is removed, note the position of the 2 driver air bag module locator pins on the steering wheel for installation. Disconnect the driver air bag module and horn switch electrical connectors and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight-ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door to allow access to the passenger air bag electrical connector. - If equipped, disconnect the glove compartment door dampener. 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat. The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical. 21. Release the RH second row safety belt retractor D-ring cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7451 22. Remove the bolt and the RH second row safety belt retractor D-ring. 23. Remove the cover and the RH C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the RH C-pillar trim panel. 25. Disconnect the RH safety canopy module electrical connector. 26. Release the LH second row safety belt retractor D-ring cover. 27. Remove the bolt and the LH second row safety belt retractor D-ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7452 28. Remove the cover and the LH C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver C-pillar trim panel. 30. Disconnect the LH safety canopy module electrical connector. 31. NOTE: There are 2 similar connectors under the driver seat. The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the Smart Junction Box (SJB). 33. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 32 (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 install the driver front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7453 4. Connect the LH safety canopy module electrical connector. 5. Install the LH C-pillar trim panel and attach the rear door weatherstrip. 6. Install the LH C-pillar trim panel nut and cover. 7. Install the LH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the LH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the RH safety canopy module electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7454 10. Install the RH C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger C-pillar trim panel nut and cover. 12. Install the RH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 13. Attach the RH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Extract and retract the safety belt between the full extension and stowed positions. - If excessive effort or binding is present, install a new safety belt buckle retractor and tongue assembly as necessary. For additional information, refer to Seat Belt Systems. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7455 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. NOTICE: The clockspring 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 horn switch and 2 driver air bag module electrical connectors. 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. NOTE: Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. 23. If equipped, install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. If equipped, connect the adjustable pedals switch connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7456 25. Install the lower steering column opening cover and 3 screws. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 32 (10A) to the SJB and install the cover. 28. 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. 29. 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 air bag SRS fault is present, the air bag warning indicator will either: - fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate 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 will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the RCM using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair Glove Compartment NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Open the glove compartment. 2. NOTICE: Forcing the glove compartment past the stops will damage the dampener. If equipped, disconnect the dampener. 3. Release the stops. 4. Remove the 3 glove compartment screws and the glove compartment. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Page 7460 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner All vehicles 1. Position aside the front and rear door weatherstrips. 2. If equipped, remove the roof opening panel trim ring. 3. Remove the LH and RH A-pillar trim panels. For additional information, refer to A-Pillar Trim Panel See: Trim Panel/Service and Repair/A-Pillar Trim Panel. 4. Remove the 2 wiring harness pin-type retainers from the A-pillar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7464 5. Open and fully lower the glove compartment. - Release the glove compartment tabs. 6. If equipped, disconnect the satellite radio antenna. 7. Remove the pin-type retainer and disconnect the electronic compass/auto-dimming rear view mirror electrical connector. 8. If equipped, separate the satellite antenna cable from the wiring harness. 9. If equipped, remove the electronic compass sensor. 10. If equipped, disconnect the auto-dimming mirror electrical connector. 11. Remove the LH and RH sun visors. - Remove the 6 sun visor screws. - If equipped, disconnect the electrical connectors. 12. Remove the LH and RH sun visor clips. - Remove the 2 sun visor clip screws. 13. If equipped, remove the overhead console. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7465 - Pull the overhead console downward to release the overhead console retaining clips. - Disconnect the electrical connectors. 14. If equipped, remove the DVD player. 15. Remove the LH and RH B-pillar trim panels. For additional information, refer to B-Pillar Trim Panel See: Trim Panel/Service and Repair/B-Pillar Trim Panel. 16. Remove the LH and RH C-pillar trim panels. For additional information, refer to C-Pillar Trim Panel See: Trim Panel/Service and Repair/C-Pillar Trim Panel. 17. Remove the LH and RH D-pillar trim panels. For additional information, refer to D-Pillar Trim Panel See: Trim Panel/Service and Repair/D-Pillar Trim Panel. Vehicles with safety canopies 18. Remove the 4 garment hangers. - Open the access panel. - Remove the garment hanger screws. Vehicles without safety canopies 19. NOTICE: To prevent damage to the garment hanger retainer, use a 3/16-inch flat-blade screwdriver for this step. NOTE: The garment hanger is shown without the roof sheet metal 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 2 garment hangers. 1. Open the access cover. 2. Insert the flat-blade screwdriver fully into the garment slot. 3. Rotate the screwdriver 90 degrees so that the screwdriver spreads the metal retainer clip. Remove the plastic garment hanger. Expedition EL/Navigator L 20. Open the third row safety belt anchor bolt cover. 21. Remove the third row seat safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 22. Remove the third row safety belt. All vehicles 23. Remove the 2 center pin-type retainers. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7466 24. Remove the 2 rear pin-type retainers. Vehicles with rear climate control 25. Tilt the headliner to release the vent duct. All vehicles 26. Disconnect the rear electrical connector. 27. NOTICE: To avoid bending or crimping the headliner, the help of an assistant is required for this step. Remove the headliner. 28. To install, reverse the removal procedure. - Transfer parts as necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Expedition/Navigator shown, Expedition EL/Navigator L similar. 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7471 Trim Panel: Service and Repair A-Pillar Trim Panel A-Pillar Trim Panel Removal and Installation 1. Remove the 2 A-pillar assist handle bolt covers. 2. Remove the 2 A-pillar assist handle bolts. - To install, tighten to 5 Nm (44 lb-in). 3. NOTE: Carefully rotate the A-pillar trim panel during this step. Remove the A-pillar trim panel. - Pull the A-pillar trim panel outward to release the A-pillar retaining clips. 4. NOTICE: To avoid damage to the A-pillar trim panel, remove any retaining clips from the body and attach them to the A-pillar trim panel before installing. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7472 Trim Panel: Service and Repair B-Pillar Trim Panel B-Pillar Trim Panel Removal and Installation Upper and lower 1. Move the front seat to the full forward position. 2. NOTE: Position the shoulder safety belt guide to the lowest position. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide cover. - Detach the top of the shoulder safety belt guide cover. - Rotate the shoulder safety belt guide cover 90 degrees and remove from the safety belt guide bolt. 3. Remove the shoulder safety belt guide. - Remove the shoulder safety belt guide bolt. To install, tighten to 40 Nm (30 lb-ft). - Remove the shoulder safety belt guide. 4. NOTICE: To avoid damage to the upper B-pillar trim panel, remove any retaining clips from the body and attach them to the upper B-pillar trim panel before installing. Remove the upper B-pillar trim panel. 1. Remove the bolt cover and bolt. - To install, tighten to 8 Nm (71 lb-in). 2. Remove the upper B-pillar trim panel by pulling outward to release the clips. Lower Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7473 5. Remove the front and rear door scuff plates. 6. NOTICE: To avoid damage to the lower B-pillar trim panel, remove any retaining clips from the body and attach them to the lower B-pillar trim panel before installing. Pull outward to release the lower B-pillar trim panel clips and reposition the lower B-pillar trim panel. 7. Remove the front safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 8. Feed the safety belt through the lower B-pillar trim panel and remove. Upper and lower 9. To install, reverse the removal procedure. - When installing the upper B-pillar trim panel, insert the safety belt guide slide into the upper B-pillar trim panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7474 Trim Panel: Service and Repair C-Pillar Trim Panel C-Pillar Trim Panel Removal and Installation All vehicles 1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1. Position the shoulder safety belt cover upward. 2. Remove the safety belt guide bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the shoulder safety belt guide. 2. Detach the safety belt holder pin-type retainer. 3. Remove the C-pillar trim panel fastener cover. Expedition EL/Navigator L only 4. Remove the C-pillar trim panel nut. - To install, tighten to 8 Nm (71 lb-in). All vehicles except Expedition EL/Navigator L 5. Remove the C-pillar trim panel bolt. - To install, tighten to 8 Nm (71 lb-in). All vehicles 6. NOTICE: To avoid damage to the C-pillar trim panel, remove any retaining clips from the body and attach them to the C-pillar trim panel before installing. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7475 Remove the C-pillar trim panel. - Pull the C-pillar trim panel outward to release the C-pillar trim panel retaining clips. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7476 Trim Panel: Service and Repair D-Pillar Trim Panel D-Pillar Trim Panel Removal and Installation All vehicles except Expedition EL/Navigator L NOTE: Right side with power vent windows shown, all others similar. 1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1. Position the shoulder safety belt guide cover upward. 2. Remove the shoulder safety belt guide bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the shoulder safety belt guide. All vehicles 2. Remove the rear upper headliner trim panel. - Pull the rear upper headliner trim panel downward to release the retaining clips. 3. NOTICE: To avoid damage to the D-pillar trim panel, remove any retaining clips from the body and attach them to the D-pillar trim panel before installing. Remove the D-pillar trim panel. 1. Disengage the upper clip by pulling downward. 2. Unseat the D-pillar trim panel and rotate forward to remove. - If equipped, disconnect the speaker electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7477 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition Navigator Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Page 7481 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: Individual 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 the new lock cylinder to the current code of the vehicle. 1. Remove the exterior front door handle. For additional information, refer to Exterior Front Door Handle See: Doors, Hood and Trunk/Doors/Front Door/Front Door Handle/Front Door Exterior Handle/Service and Repair. 2. Remove the retainer and the front door lock cylinder. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Key: Testing and Inspection Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Integrated Keyhead Transmitter (IKT) 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 and the vehicle does not start until 2 keys are programmed to the vehicle. This procedure also erases the Integrated Keyhead Transmitter (IKT) identification codes (TICs) from the Smart Junction Box (SJB), preventing the erased IKT from operating the Remote Keyless Entry (RKE) functions on the vehicle. NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS 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. One or both of them may be an IKT or a standard PATS key. 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 IC 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. Follow all Integrated Diagnostic System (IDS) screen instructions until the key erase procedure completes. The scan tool will also instruct to program 2 keys to complete the process. 4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be removed at this time). 5. NOTE: The RKE data transfer takes place between the key and the IC first. After both keys are programmed into the IC, the RKE data transfers from the IC to the SJB. Until the final data transfer takes place into the SJB, the RKE functions do not operate. NOTE: IKT keys require a 6-second programming time frame for the RKE data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the first PATS key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 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 a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 8. The vehicle should now start with both ignition keys and the RKE transmitter portion of an IKT should function. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7491 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 Instrument Cluster (IC) SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the 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. If the SPAREKEY PID reads DISABLED, the key programming using two programmed keys procedure cannot function. The switch is set to ENABLE when the vehicle is built. The switch does not affect the Key Programming Using Diagnostic Equipment procedure or the Spare Key Programming - Unlimited Key Mode procedure or the Spare Key Programming - Using Diagnostic Equipment procedure. 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, 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: "Customer Spare Key Programming Enable" (or "Customer Spare Key Programming Disable"). - "Customer Spare Key Programming Enable" - spare key programming procedure is accessible. - "Customer Spare Key Programming Disable" - spare key programming procedure is not accessible. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7492 Key: Testing and Inspection Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure works only if 2 or more programmed ignition keys are available. If 2 programmed keys are not available, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment. NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate. If this 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 PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the anti-theft indicator proves-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 portion 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 Instrument Cluster (IC) during this programming procedure, but only if the PID SPAREKEY is ENABLED. 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 PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure ends. 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 (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, 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 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, maintaining the key in the ON position for a minimum of 6 seconds (the additional 3 second time frame allows for the Remote Keyless Entry (RKE) data transfer to take place, if programming an Integrated Keyhead Transmitter (IKT) key). 6. Start the vehicle with the new key(s). 7. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7493 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 (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle. 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed to 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 PID UNL_KEY_ID 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 PID UNL_KEY_ID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. 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 . 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. 8. Insert the first Passive Anti-Theft System (PATS) key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an Integrated Keyhead Transmitter (IKT) key). 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 (6 seconds if it is an IKT key). 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7494 NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. 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 . 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. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 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 (6 seconds if it is an IKT key). 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 PID SPAREKEY 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 PID SPAREKEY must be enabled. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7495 Key: Testing and Inspection Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment Integrated Keyhead Transmitter (IKT) 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 and the vehicle does not start until 2 keys are programmed to the vehicle. This procedure also erases the Integrated Keyhead Transmitter (IKT) identification codes (TICs) from the Smart Junction Box (SJB), preventing the erased IKT from operating the Remote Keyless Entry (RKE) functions on the vehicle. NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS 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. One or both of them may be an IKT or a standard PATS key. 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 IC 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. Follow all Integrated Diagnostic System (IDS) screen instructions until the key erase procedure completes. The scan tool will also instruct to program 2 keys to complete the process. 4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be removed at this time). 5. NOTE: The RKE data transfer takes place between the key and the IC first. After both keys are programmed into the IC, the RKE data transfers from the IC to the SJB. Until the final data transfer takes place into the SJB, the RKE functions do not operate. NOTE: IKT keys require a 6-second programming time frame for the RKE data transfer to take place, while standard PATS keys only require a minimum of 3 seconds. Turn the first PATS key to the ON position for a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 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 a minimum of 6 seconds (this additional 3 second time frame allows for the RKE data transfer to take place). 8. The vehicle should now start with both ignition keys and the RKE transmitter portion of an IKT should function. 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7496 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 Instrument Cluster (IC) SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the 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. If the SPAREKEY PID reads DISABLED, the key programming using two programmed keys procedure cannot function. The switch is set to ENABLE when the vehicle is built. The switch does not affect the Key Programming Using Diagnostic Equipment procedure or the Spare Key Programming - Unlimited Key Mode procedure or the Spare Key Programming - Using Diagnostic Equipment procedure. 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, 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: "Customer Spare Key Programming Enable" (or "Customer Spare Key Programming Disable"). - "Customer Spare Key Programming Enable" - spare key programming procedure is accessible. - "Customer Spare Key Programming Disable" - spare key programming procedure is not accessible. Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure works only if 2 or more programmed ignition keys are available. If 2 programmed keys are not available, refer to Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment. NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate. If this 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 PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the anti-theft indicator proves-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 portion 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 Instrument Cluster (IC) during this programming procedure, but only if the PID SPAREKEY is ENABLED. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7497 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 PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure ends. 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 (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, 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 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, maintaining the key in the ON position for a minimum of 6 seconds (the additional 3 second time frame allows for the Remote Keyless Entry (RKE) data transfer to take place, if programming an Integrated Keyhead Transmitter (IKT) key). 6. Start the vehicle with the new key(s). 7. 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. 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 (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, no matter how many keys are programmed to the vehicle. 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed to 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7498 2. NOTE: If the PID UNL_KEY_ID 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 PID UNL_KEY_ID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. 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 . 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. 8. Insert the first Passive Anti-Theft System (PATS) key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an Integrated Keyhead Transmitter (IKT) key). 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 (6 seconds if it is an IKT key). 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, 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 . 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. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds (6 seconds if it is an IKT key). 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 (6 seconds if it is an IKT key). 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 PID SPAREKEY 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 PID SPAREKEY must be enabled. Spare Key Programming - Using Diagnostic Equipment Spare Key Programming - Using Diagnostic Equipment Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7499 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 Passive Anti-Theft System (PATS) keys to be programmed. The number of keys that are programmed into the PATS can be determined by viewing the Instrument Cluster (IC) PID N_KEYCODE. NOTE: When in the unlimited key mode (after the first 2 keys have been programmed to the vehicle), the N_KEYCODE PID will always read 2, 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, 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". If the "ERASE" selection is made, all of the keys are erased from the system. From the scan tool menu select: "Program additional ignition key". 4. Turn the key to the OFF position and disconnect the scan tool. 5. Start the vehicle with the new PATS key. The vehicle starts 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment > Page 7500 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 7505 Keyless Entry Key-Pad: Testing and Inspection Keyless Entry Keypad Code Programming Programming a Personal Code and Keypad Association to Memory Seats and Mirrors (If Equipped) NOTE: If the wrong code has been entered 7 times (35 consecutive button presses), the keypad will go into an anti-scan mode. This mode disables the keypad for one minute and the keypad illumination will flash. The anti-scan feature will turn off after one minute of keypad inactivity, after pressing the UNLOCK button on the Remote Keyless Entry (RKE) transmitter, or after the ignition key has been turned to the ON position. NOTE: The factory set code cannot be associated with a memory setting. 1. Enter the permanent factory keyless entry keypad code. 2. Within 5 seconds, press the 1/2 button on the keypad. 3. Enter the new 5-digit keyless entry keypad code. Each number must be entered within 5 seconds of each other. 4. To associate the entry code with a memory setting, enter a sixth digit to indicate which driver should be set in a memory recalled by the personal entry code: Pressing the 1/2 button recalls driver 1 settings - Pressing the 3/4 button recalls driver 2 settings - Pressing other keypad buttons or not pressing a keypad button as a sixth digit does not set a driver and will not recall a memory setting 5. The doors will lock then unlock to confirm the new code is programmed. Erasing the Personal Codes NOTE: If the wrong code has been entered 7 times (35 consecutive button presses), the keypad will go into an anti-scan mode. This mode disables the keypad for one minute and the keypad illumination will flash. The anti-scan feature will turn off after one minute of keypad inactivity, after pressing the UNLOCK button on the RKE transmitter, or after the ignition key has been turned to the ON position. 1. Enter the permanent factory keyless entry keypad code. 2. Within 5 seconds, press the 1/2 button on the keypad and release. 3. Within 5 seconds, press and hold the 1/2 button on the keypad for 2 seconds. 4. All personal codes are now erased and only the permanent factory keyless entry keypad code will work. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 7506 Keyless Entry Key-Pad: Service and Repair Keyless Entry Keypad Removal and Installation 1. Remove the exterior mirror. 2. Remove the front door outer glass weatherstrip. - Disconnect the electrical connector. 3. Release the tabs and remove the keyless entry keypad. - Disconnect the keypad harness retaining clips from the weatherstrip. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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: This procedure is for programming conventional keyfobs only. The Remote Keyless Entry (RKE) transmitter of the Integrated Keyhead Transmitter (IKT) is programmed automatically during the Passive Anti-Theft System (PATS) programming. For additional information, refer to Key Programming Using Two Programmed Keys or Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment in Antitheft and Alarm Systems to program the IKT. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: All RKE transmitters must be programmed at the same time. NOTE: Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the transmitters will not be programmed. 1. Electronically unlock the door locks using the door lock control switch. 2. Cycle the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10 seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the programming sequence ends (the doors lock and unlock to confirm that programming is complete). Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (4) of RKE transmitters have been programmed. 5. Check the operation of the RKE transmitter. If the door locks do not respond for the programmed RKE transmitter(s), 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 RKE transmitters are attempted to be programmed.) Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7511 Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming Autolock and Auto-Unlock Programming Programming the Autolock Feature Using the Door Lock Control Switch NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped. NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door lock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock and lock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the unlock button and then the lock button on the door lock control switch within 5 seconds to enable/disable the autolock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Auto-Unlock Feature Using the Door Lock Control Switch NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped. NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the lock button on the door lock control switch then the unlock button to enable/disable the auto-unlock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Autolock Feature Using the Keyless Entry Keypad NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure needs to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7512 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button. 4. Release the 3/4 button. The horn chirps once if the autolocks are disabled, or chirps once followed by a honk if the autolocks are enabled. Programming the Auto-Unlock Feature Using the Keyless Entry Keypad NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button twice. 4. Release the 3/4 button. The horn chirps once if auto-unlock is disabled, or chirps once followed by a honk if auto-unlock is enabled. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7513 Keyless Entry Transmitter: Testing and Inspection Remote Memory Activation Remote Memory Activation 1. Position the driver seat, adjustable pedals, steering column and exterior mirror to the desired positions. 2. Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds when the memory store is done. Continue to hold until a second tone is heard after 5 seconds. 3. Within 3 seconds, press the LOCK button on the Remote Keyless Entry (RKE) transmitter. 4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7514 Keyless Entry Transmitter: Testing and Inspection Remote Memory Deactivation Remote Memory Deactivation 1. Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds when the memory store is done. Continue to hold until a second tone is heard after 5 seconds. 2. Within 3 seconds, press the UNLOCK button on the Remote Keyless Entry (RKE) transmitter. 3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE transmitter. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7515 Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter Programming Remote Keyless Entry (RKE) Transmitter Programming NOTE: This procedure is for programming conventional keyfobs only. The Remote Keyless Entry (RKE) transmitter of the Integrated Keyhead Transmitter (IKT) is programmed automatically during the Passive Anti-Theft System (PATS) programming. For additional information, refer to Key Programming Using Two Programmed Keys or Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment in Antitheft and Alarm Systems to program the IKT. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment NOTE: All RKE transmitters must be programmed at the same time. NOTE: Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the transmitters will not be programmed. 1. Electronically unlock the door locks using the door lock control switch. 2. Cycle the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10 seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the programming sequence ends (the doors lock and unlock to confirm that programming is complete). Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (4) of RKE transmitters have been programmed. 5. Check the operation of the RKE transmitter. If the door locks do not respond for the programmed RKE transmitter(s), 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 RKE transmitters are attempted to be programmed.) Autolock and Auto-Unlock Programming Autolock and Auto-Unlock Programming Programming the Autolock Feature Using the Door Lock Control Switch NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped. NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door lock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock and lock buttons must be pressed within 5 seconds of each other. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7516 Within 30 seconds of entering the programming mode, press the unlock button and then the lock button on the door lock control switch within 5 seconds to enable/disable the autolock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Auto-Unlock Feature Using the Door Lock Control Switch NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped. NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other. Within 30 seconds of entering the programming mode, press the lock button on the door lock control switch then the unlock button to enable/disable the auto-unlock feature. The horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Programming the Autolock Feature Using the Keyless Entry Keypad NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure needs to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button. 4. Release the 3/4 button. The horn chirps once if the autolocks are disabled, or chirps once followed by a honk if the autolocks are enabled. Programming the Auto-Unlock Feature Using the Keyless Entry Keypad NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature. NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Enter the factory set 5 digit entry code. 2. Press and hold the 3/4 button. 3. While holding the 3/4 button, press and release the 7/8 button twice. 4. Release the 3/4 button. The horn chirps once if auto-unlock is disabled, or chirps once followed by a honk if auto-unlock is enabled. Remote Memory Activation Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7517 Remote Memory Activation 1. Position the driver seat, adjustable pedals, steering column and exterior mirror to the desired positions. 2. Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds when the memory store is done. Continue to hold until a second tone is heard after 5 seconds. 3. Within 3 seconds, press the LOCK button on the Remote Keyless Entry (RKE) transmitter. 4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Remote Memory Deactivation Remote Memory Deactivation 1. Press and hold either memory button (1 or 2) for 5 seconds. A tone will be heard after 1-1/2 seconds when the memory store is done. Continue to hold until a second tone is heard after 5 seconds. 2. Within 3 seconds, press the UNLOCK button on the Remote Keyless Entry (RKE) transmitter. 3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE transmitter. Perimeter Lighting Feature Programming Perimeter Lighting Feature Programming Programming the Perimeter Lighting Feature Using the Door Lock Control Switch NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the ON position. 2. Press the unlock button on the door lock control switch 3 times. 3. Turn the ignition switch from the ON to the OFF position. 4. Press the unlock button on the door lock control switch 3 times. 5. Turn the ignition switch to the ON position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock button must be pressed twice within 5 seconds. Within 30 seconds of entering the programming mode, press the unlock button on the door lock control switch twice to enable/disable the perimeter lighting feature. The horn chirps once if the perimeter lighting is disabled or a chirp followed by a honk if the perimeter lighting is enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. 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 turn signals flash twice to indicate the mode change. 2. Repeat Step 1 to enable/disable the stepped unlocking feature. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front Power Door Lock Actuator: Locations Door Lock Actuator, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7523 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7524 Power Door Lock Actuator: Locations Door Lock Actuator, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7525 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7526 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7527 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7530 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7531 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7532 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 7533 Power Door Lock Actuator: Service and Repair Door Lock Actuator Removal and Installation 1. Remove the 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 or Rear Door Latch See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement. 2. Release the locking tab and remove the door lock actuator. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side Power Door Lock Switch: Locations Door Lock Switch, Passenger Side Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 7538 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 7539 Power Door Lock Switch: Locations Door Lock Switch, Driver Side Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 7540 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 7543 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7544 Power Door Lock Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7545 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7551 Memory Positioning Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7552 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7553 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7554 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7555 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. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed, it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 7559 Ford Expedition 2wd Workshop Manual (V8-5.4L (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: If equipped with power folding mirrors, they must be synchronized any time the mirrors have been folded or unfolded without using the mirror control switch. For additional information, refer to Exterior Mirror Motor Synchronization - Power Folding See: Testing and Inspection/Programming and Relearning. 1. Remove the mirror glass. For additional information, refer to Exterior Mirror Glass See: Service and Repair/Exterior Mirror Glass. 2. Remove the 3 exterior mirror motor screws and exterior mirror motor. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. - If equipped with power folding mirrors, they must be synchronized. For additional information, refer to Exterior Mirror Motor Synchronization - Power Folding See: Testing and Inspection/Programming and Relearning. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7566 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7567 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7568 Power Mirror Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7569 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7570 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7571 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Remove the driver front door trim panel. 2. Remove the exterior mirror control switch. 1. Depress the locking tabs. 2. Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7576 Memory Positioning Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7577 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7578 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7579 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7580 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. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed, it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Page 7584 Power Seat Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Page 7585 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations Power Trunk / Liftgate Control Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 7589 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 7590 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 7591 Power Trunk / Liftgate Control Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 7592 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Liftgate Latch Remote Control Power Trunk / Liftgate Control Module: Service and Repair Liftgate Latch Remote Control Liftgate Latch Remote Control Removal and Installation NOTE: The liftgate latch remote control is available with power liftgate only. 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. NOTICE: Be careful not to kink the liftgate latch actuating cable while disconnecting it from the latch. Disconnect the liftgate latch. 1. Release the liftgate latch actuator rod. 2. Disconnect the liftgate latch actuating cable. 4. Remove 3 bolts and position the liftgate latch remote control aside. - To install, tighten to 11 Nm (8 lb-in). 5. Disconnect the electrical connectors and remove the liftgate latch remote control. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Liftgate Latch Remote Control > Page 7595 Power Trunk / Liftgate Control Module: Service and Repair Liftgate/Trunk Module (LTM) Liftgate/Trunk Module (LTM) Removal and Installation 1. Remove the rear quarter trim panel. 2. Remove the Liftgate/Trunk Module (LTM). 1. Disconnect the electrical connectors. 2. Remove the bolt. - To install, tighten to 9 Nm (80 lb-in). 3. To install, reverse the removal procedure. - Initialize the power liftgate. For additional information, refer to Power Liftgate Initialization See: Doors, Hood and Trunk/Trunk / Liftgate/Service and Repair/Procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations Auxiliary Step / Running Board Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7599 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7600 Auxiliary Step / Running Board Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7601 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7602 Auxiliary Step / Running Board Module: Service and Repair Power Running Board (PRB) Module Removal and Installation 1. Remove the LH B-pillar trim panel. 2. Disconnect the Power Running Board (PRB) module electrical connectors. 3. Remove the 2 bolts and the PRB module assembly. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module Seat Heater Control Module: Locations Rear Heated Seat Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module > Page 7607 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module > Page 7608 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module Seat Heater Control Module: Diagrams Rear Heated Seat Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 7611 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 7612 Seat Heater Control Module: Diagrams Dual Climate Controlled Seat Module (DCSM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 7613 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 7614 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7617 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7618 Seat Heater Control Module: Service and Repair Dual Climate Controlled Seat Module (DCSM) Dual Climate Controlled Seat Module (DCSM) Removal and Installation 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. NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Seats/Service and Repair/Front Seats/Seat - Exploded View, Front. 1. When installing a new Dual Climate Controlled Seat Module (DCSM), carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Position the front passenger seat fully upward and remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. 3. Release the 2 tabs and slide out the DCSM. 4. Remove the DCSM. - Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. 5. To install, reverse the removal procedure. 6. If a new DCSM has been installed, carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7619 Seat Heater Control Module: Service and Repair Heated Seat Module - Second Row Heated Seat Module - Second Row NOTE: Bottom of floor console shown. Removal and Installation 1. Remove the front floor console. 2. Disconnect the 2 heated seat module electrical connectors at the bottom of the front floor console. 3. Remove the screw and un-hook the heated seat module. 4. To install, reverse the removal procedure. 5. Carry out the auto-configuration sequence to program the heated seat module for use with a dual momentary switch. - Start the vehicle and push the low button on either heated seat switch. - Operate the heated seats, monitor the indicators and verify the system is operating correctly in high and low. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7623 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7624 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 7634 Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel Motor Roof Opening Panel Motor Removal NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when 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. Disconnect the roof opening panel motor electrical connector. 3. Remove the roof opening panel motor. - Remove the 3 screws. Installation 1. Connect the roof opening panel motor electrical connector. 2. NOTE: When installing the roof opening panel motor/module, align the 3 attach holes before engaging the drive gear into the roof opening panel drive cable. Do not rotate the motor assembly after the drive gear is engaged with the roof opening panel drive cable. Otherwise, the cable can bind. Install the roof opening panel motor. - Align the attach holes, then install the 3 screws and tighten to 4 Nm (35 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7635 3. Connect the overhead console electrical connectors. 4. Initialize the roof opening panel motor/module. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 5. Disconnect the overhead console electrical connectors. 6. Install the headliner. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection Sunroof / Moonroof Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 7639 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 7644 Sunroof / Moonroof Track: Service and Repair Roof Opening Panel Rear Trough Guide Roof Opening Panel Rear Trough Guide Removal and Installation NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when 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 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 2 plastic trough guide retaining screws and the trough from the trough guide assembly. - To install, tighten to 1 Nm (9 lb-in). 3. Disconnect the trough guide rods from the lifter arm assemblies. 4. Slide the trough guide back to the slot (approximately 15 mm [0.6 in]) cut in track. - Carefully twist trough guide through the slot in the track to remove. 5. Inspect the trough guide assembly for damage. If damage is found, inspect the track for broken pieces and remove them. 6. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 7649 Sunroof / Moonroof Windguard: Service and Repair Air Deflector Air Deflector Removal and Installation 1. Open the roof opening panel. 2. NOTE: RH side shown, LH side similar. Remove the 2 plastic air deflector screws. - To install, tighten to 1 Nm (9 lb-in). 3. Raise the front of the air deflector. 4. Slide the air deflector toward the rear, then lift up to release it from the pivot shafts. 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 7654 Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel Frame Roof Opening Panel Frame Removal and Installation NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when 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. Disconnect the electrical connector. 3. Remove the roof opening panel frame. 1. Disconnect the 4 roof opening panel drain hoses. 2. Remove the 11 bolts. - To install, tighten to 10 Nm (89 lb-in). 3. Remove the roof opening panel frame. 4. To install, reverse the removal procedure. If a new roof opening panel frame is being installed, transfer the existing roof opening panel motor, air deflector, rear trough, roof opening panel glass and roof opening panel shield onto the new frame assembly. Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7658 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7659 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 7664 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, including: whenever the roof opening panel motor has been removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel frame has been installed. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 1. NOTE: The roof opening panel glass must be in the CLOSED position. Remove the 4 roof opening panel glass screws. 2. Remove the roof opening panel glass. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 7665 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield Roof Opening Panel Shield Removal and Installation NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when 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 roof opening panel glass. For additional information, refer to Roof Opening Panel Glass See: Roof Opening Panel Glass. 2. Remove the water trough. 1. Remove the 2 screws. - To install, tighten to 1 Nm (9 lb-in). 2. Remove the water trough. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: Customer Interest Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 7675 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 7676 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 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 7682 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 7683 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 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 7684 Sunroof / Moonroof Weatherstrip: Service and Repair Roof Opening Panel Weatherstrip Removal NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when 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 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. Place roof opening panel, topside up, on a worktable. Take care to support the glass assembly from below to prevent damaging the mounting tabs. 3. Remove the old roof opening panel weatherstrip by pulling up on the weatherstrip. Installation 1. Place a new weatherstrip into position on the glass assembly, with the splice (seam) on the passenger side. 2. Starting with the corners, push the weatherstrip into position. Continue pushing the weatherstrip into position around the glass assembly until complete. Use a plastic or rubber hammer if necessary. 3. Install the roof opening panel. For additional information, refer to Roof Opening Panel Glass See: Sunroof / Moonroof Panel/Service and Repair/Roof Opening Panel Glass. 4. Align the roof panel. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. 5. Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7690 Memory Positioning Module: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7691 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7692 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7693 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7694 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. Upload the module configuration information from the DSM into the scan tool. 2. NOTE: The module is accessed with the seat fully in the UP position. Position the DSM forward to remove it from the bracket. 3. Disconnect the battery. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: Once the module is installed, it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 7698 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7703 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7704 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7705 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7706 Power Seat Motor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7707 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7708 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7709 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7710 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7711 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7712 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7713 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7714 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7715 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7716 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7717 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7718 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Passenger Seat Rear Height Motor > Page 7719 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor Power Seat Motor: Diagrams Passenger Seat Horizontal Motor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7722 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7723 Power Seat Motor: Diagrams Passenger Seat Front Height Motor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7724 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7725 Power Seat Motor: Diagrams Passenger Seat Rear Height Motor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7726 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7727 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7728 Power Seat Motor: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7729 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7730 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7731 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7732 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7733 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7734 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7735 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 7736 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7739 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7740 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7741 Power Seat Motor: Service and Repair Power-Fold Seat Motor Power-Fold Seat Motor Removal and Installation NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. 1. Remove the load floor panel. 2. Remove the 2 bolts and mid-floor panel support. - Release the 3 pin-type retainers. 3. Disconnect the power seat motor electrical connector and detach the wiring harness. 4. Remove the bracket-to-pivot bolt and bushing from the power-fold seat motor. - Note bushing shoulder position for correct installation. - To install, tighten to 30 Nm (22 lb-ft). 5. Remove the bracket-to-latch bolt and power-fold seat motor. - Slide the power-fold seat motor and bracket away from the latch and torque shaft. For installation, slightly rotate the torque shaft until seated into the power-fold seat motor. - To install, tighten to 30 Nm (22 lb-ft). 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 7746 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 7747 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 7748 Power Seat Motor Position Sensor: Locations Height Sensor, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 7749 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 7750 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 7751 Power Seat Motor Position Sensor: Locations Height Sensor, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 7752 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 7755 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 7756 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 7757 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 7758 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Page 7762 Power Seat Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Page 7763 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 7768 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 7769 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 7770 Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 7771 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 7772 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 7773 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 7774 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left Power Seat Switch: Diagrams Seat Control Switch, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 7777 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 7778 Power Seat Switch: Diagrams Seat Control Switch, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 7779 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 7780 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 7781 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left Power Seat Switch: Testing and Inspection Seat Control Switch, 10-Way - Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7784 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7785 Power Seat Switch: Testing and Inspection Seat Control Switch, 10-Way - Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7786 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7787 Power Seat Switch: Testing and Inspection Seat Control Switch, 6-Way - Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7788 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7789 Power Seat Switch: Testing and Inspection Seat Control Switch, 6-Way - Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7790 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7791 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7792 Power Seat Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7793 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7794 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7795 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7796 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7797 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7798 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7799 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7800 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7801 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7802 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 7803 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7806 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7807 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7808 Power Seat Switch: Service and Repair Memory Set Switch Memory Set Switch Removal and Installation 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: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. All seats 1. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Driver seat side shield with insert 2. Release the retainers and remove the insert from the side shield. - Disconnect the electrical connectors. Driver seat side shield with cover 3. Remove the front side shield screw. 4. Remove the side shield cover. All seats 5. Release the clips and remove the memory SET switch. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7809 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7814 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7815 1. For additional information, refer to the procedures. Seat Backrest - Front Seat Backrest - Front 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: 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. NOTE: If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and nuts must be installed. The seat back frame should be installed new if necessary. NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. NOTE: Note all backrest wire harness routing for correct installation. All seats 1. Remove the seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. If equipped, remove the manual lumbar knob. - Adjust the manual lumbar to the fully relaxed position. - Pull and remove the manual lumbar knob. Seat with side shield insert 3. Release the retainers and remove the insert from the side shield. - For power seat, disconnect the electrical connector(s). 4. Remove the front side shield screw. 5. Remove the 4 side shield screws. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7816 Seat with side shield cover 6. Remove the front side shield screw. 7. Remove the side shield cover. - Pry and release the 2 tabs at the rear of the side shield cover. - If equipped, disconnect the electrical connector(s). - Slide the cover forward and remove. 8. Remove the 5 side shield screws. All seats 9. Release the backrest lower J-strip and unzip the 2 side zippers. 10. If equipped, remove the manual lumbar actuator. - Make sure the lumbar is fully relaxed. - Remove the 2 screws and lumbar actuator. - Detach and route out the lumbar cable from the cushion. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7817 - Note cable routing for correct installation. 11. Remove the 2 side air bag module nuts. - To install, tighten to 10 Nm (89 lb-in). 12. Position the backrest foam aside and remove the side air bag module from the backrest frame. Then slide the side air bag module out of the seat backrest cover deployment chute. For installation, position the locator pin and mounting studs through the holes in the deployment chute and backrest frame. 13. Disconnect the electrical connector and remove the side air bag module. 14. Detach the 3 pin-type retainers and side air bag wiring harness. 15. For power and climate controlled seat, disconnect the backrest wiring harness electrical connector and route the wire harness from the cushion. 16. Release the cushion cover fastener from the rear inboard side. 17. Remove the 4 backrest frame-to-seat track bolts and backrest. - To install, tighten to 45 Nm (33 lb-ft). 18. WARNING: Check the seat side air bag deployment chute for damage. The deployment chute must not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and deployment chute must be installed as a unit. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7818 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. To install, reverse the removal procedure. Seat - Exploded View, Second Row Seat - Exploded View, Second Row Seat Backrest - 20 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7819 Seat Cushion - 20 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7820 Seat Backrest - 40 Percent NOTE: LH seat shown, RH similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7821 Seat Cushion - 40 Percent Seat NOTE: LH seat shown, RH seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7822 1. For additional information, refer to the procedures. Seat Backrest - Second Row, 20 Percent Seat Backrest - Second Row, 20 Percent Removal and Installation NOTE: For parts identification and locations, refer to Seat - Exploded View, Second Row See: Service and Repair/Second Row Seats/Seat - Exploded View, Second Row. 1. Remove the seat. For additional information, refer to Seat - Second Row, 20 Percent See: Service and Repair/Second Row Seats/Seat - Second Row, 20 Percent. 2. Remove the screw and pivot bolt cover. - Route the attaching strap through the pivot bolt cover. 3. Release the 2 lower backrest cover J-clips. 4. Remove the pin-type retainer and detach the LH side attaching strap. 5. Remove the 2 screws and RH side shield. - Raise the backrest upright to access and remove the center screw. - Release the 2 pin-type retainers. 6. Remove the pin-type retainer and detach the RH attaching strap. - Note attaching strap routing for correct installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7823 7. Remove the safety belt anchor bolt. - To install, tighten to 55 Nm (41 lb-ft). 8. Remove the 2 pin-type retainers and lower panel. 9. Release the 3 lower backrest cover J-clips and route the RH flap through the child safety seat anchorage. 10. Release the 2 J-clips and remove the attaching straps. 11. Detach the latch release cable from the seat base. - Release the cable clamp. - Detach the cable end. 12. NOTICE: Use care when separating the cushion cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the cushion foam pad. Partially invert the backrest cover to access the backrest fasteners. 13. Position aside the foam pad and remove the 2 swivel bolts. - To install, tighten to 30 Nm (22 lb-ft). 14. Remove the pivot bolt. - To install, tighten to 55 Nm (41 lb-ft). 15. Remove the 2 backrest-to-cushion bolts. - To install, tighten to 48 Nm (35 lb-ft). 16. Remove the seat backrest. - Route out the latch release cable. - Note the cable routing for correct installation. 17. NOTE: 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 - Exploded View, Third Row Seat - Exploded View, Third Row Seat Backrest - 40 percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7824 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7825 Seat Cushion - 40 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7826 Seat Backrest - 60 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7827 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7828 Seat Cushion - 60 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7829 1. For additional information, refer to the procedures. Seat Backrest - Third Row, 40 Percent Seat Backrest - Third Row, 40 Percent Removal and Installation NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. All seats 1. Remove the seat. For additional information, refer to Seat - Third Row See: Service and Repair/Third Row Seats/Seat - Third Row. 2. Remove the 2 screws and inboard and outboard slide bracket covers. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7830 3. Release the backrest cover lower and inboard J-clips. Manual fold seat 4. Remove the manual seat cable. 1. Release the cable clamp. 2. Detach the cable end. All seats 5. Remove the outboard slide bracket-to-backrest frame and outboard slide bracket-to-outboard latch nuts. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the inboard slide bracket-to-backrest frame and inboard slide bracket-to-inboard latch nuts. - To install, tighten to 15 Nm (133 lb-in). 7. Separate the backrest from the seat and remove. 8. To install, reverse the removal procedure. Seat Backrest - Third Row, 60 Percent Seat Backrest - Third Row, 60 Percent Removal and Installation NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. All seats 1. Remove the seat. For additional information, refer to Seat - Third Row See: Service and Repair/Third Row Seats/Seat - Third Row. 2. Remove the 2 screws and inboard and outboard slide bracket covers. 3. Release the backrest cover lower and inboard J-clips. Manual fold seats 4. Remove the manual seat cable. 1. Release the cable clamp. 2. Detach the cable end. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7831 All seats 5. Remove the outboard slide bracket-to-backrest frame and outboard slide bracket-to-outboard latch nuts. - To install, tighten to 15 Nm (133 lb-in). 6. Remove the inboard slide bracket-to-backrest frame and inboard slide bracket-to-inboard latch nuts. - To install, tighten to 15 Nm (133 lb-in). 7. Separate the backrest from the seat and remove. 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7832 Seat Back: Overhaul Front Seats Seat Backrest - Front Disassembly and Assembly NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. 1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Front See: Seat Cover/Service and Repair/Front Seats/Seat Backrest Cover - Front. 2. Release the lower flap from the backrest frame hooks and remove the backrest foam pad. 3. Remove the 4 bolts and lumbar assembly. - To install, tighten to 7 Nm (62 lb-in). - If equipped, disconnect the electrical connector from the lumbar assembly. - If equipped, route out the manual lumbar cable. 4. For climate controlled seat, remove the backrest Thermo-Electric Device (TED). - Disconnect the TED electrical connector. - Remove the scrivet. - Detach the 2 retainer clips from the backrest frame support wires. 5. If equipped, disconnect the recliner motor electrical connector. 6. For power and climate controlled seat, detach the wire harness retainers and remove the backrest wiring harness. - Note the wire harness routing for correct installation. 7. To assemble, reverse the disassembly procedure. Second Row Seats Seat Backrest - Second Row, 20 Percent Disassembly and Assembly NOTE: For parts identification and locations, refer to Seat - Exploded View, Second Row See: Service and Repair/Second Row Seats/Seat - Exploded View, Second Row. 1. Remove the seat backrest. For additional information, refer to Seat Backrest - Second Row, 20 Percent See: Removal and Replacement/Second Row Seats/Seat Backrest - Second Row, 20 Percent. 2. Remove the safety belt guide cover. - Insert an appropriate tool into the holes and release the 3 locking tabs. - Detach the safety belt guide cover. - Route the safety belt webbing through the slot. 3. Remove the latch release handle bezel. - Release the upper tab and separate the bezel from the latch release handle. 4. NOTICE: Use care when separating the backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the backrest foam pad. Separate the hook-and-loop strips and invert the backrest trim cover to the row of hog rings. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7833 5. Remove all hog rings. 6. Continue inverting and remove the backrest cover. - Route the safety belt webbing through the backrest cover opening. 7. Remove the 2 pin-type retainers and foam pad. 8. Remove the safety belt retractor foam cover. 9. Remove the 2 screws and safety belt retractor cover. 10. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 11. Release the 2 tabs and detach the safety belt retractor guide. 12. Remove the safety belt retractor. - Route out the safety belt webbing, guide, tongue and anchor through the backrest frame. - Note safety belt routing for correct installation. 13. Release the pin-type retainer and detach the release cable from the backrest frame. 14. Remove the 2 screws, latch release handle and route out the cable. - Note cable routing for correct installation. 15. Remove the 2 pin-type retainers and 2 attaching straps. 16. Remove the 8 backrest support panel screws. 17. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To assemble, reverse the disassembly procedure. Seat Backrest - Third Row, 40 Percent Seat Backrest - Third Row, 40 Percent Disassembly and Assembly NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. 1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Third Row See: Seat Cover/Service and Repair/Third Row Seats/Seat Backrest Cover - Third Row. 2. Remove the bolt and the safety belt buckle. - For installation, align the anti-rotation tab. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the nut, screw and support bracket. 4. Remove the 2 inboard latch-to-backrest frame bolts and the inboard latch. - To install, tighten to 40 Nm (30 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7834 5. Remove the outboard latch-to-cushion frame bolt and the outboard latch. - To install, tighten to 30 Nm (22 lb-ft). 6. Remove the 6 screws and the backrest support panel. 7. To assemble, reverse the disassembly procedure. Seat Backrest - Third Row, 60 Percent Seat Backrest - Third Row, 60 Percent Disassembly and Assembly NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. 1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Third Row See: Seat Cover/Service and Repair/Third Row Seats/Seat Backrest Cover - Third Row. 2. Remove the safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the backrest foam pad. 4. Remove the nut, screw and support bracket. 5. Remove the outboard latch-to-cushion frame bolt and outboard latch. - To install, tighten to 35 Nm (26 lb-ft). 6. Remove the 2 inboard latch-to-backrest frame bolts and inboard latch. - To install, tighten to 55 Nm (41 lb-ft). 7. Remove the 4 screws and safety belt retractor cover. 8. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 9. Pinch to release the safety belt guide and remove the safety belt retractor. - Route through the backrest frame. 10. Remove the 15 screws and backrest support panel. 11. Remove the bolt and child safety seat tether anchor. - To install, tighten to 15 Nm (133 lb-in). 12. To assemble, reverse the disassembly procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7839 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7840 Seat Cover: Service and Repair Second Row Seats Seat - Exploded View, Second Row Seat - Exploded View, Second Row Seat Backrest - 20 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7841 Seat Cushion - 20 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7842 Seat Backrest - 40 Percent NOTE: LH seat shown, RH similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7843 Seat Cushion - 40 Percent Seat NOTE: LH seat shown, RH seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7844 1. For additional information, refer to the procedures. Seat Backrest Cover - Second Row, 20 Percent Seat Backrest Cover - Second Row, 20 Percent Removal and Installation NOTE: For parts identification and locations, refer to Seat - Exploded View, Second Row See: Service and Repair/Second Row Seats/Seat - Exploded View, Second Row. 1. Remove the screw and pivot bolt cover. - Route the attaching strap through the pivot bolt cover. 2. Release the 2 lower backrest cover J-clips. 3. Remove the pin-type retainer and detach the LH side attaching strap. 4. Remove the 2 screws and RH side shield. - Raise the backrest upright to access and remove the center screw. - Release the 2 pin-type retainers. 5. Remove the pin-type retainer and detach the RH attaching strap. - Note attaching strap routing for correct installation. 6. Remove the safety belt anchor bolt. - To install, tighten to 55 Nm (41 lb-ft). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7845 7. Remove the 2 pin-type retainers and lower panel. 8. Release the 3 lower J-clips and route the RH flap through the child safety seat anchorage. 9. Detach the 2 J-clips and remove the attaching straps. 10. Remove the safety belt guide cover. - Insert an appropriate tool into the holes and release the 3 locking tabs. - Detach the safety belt guide cover. - Route the safety belt webbing through the slot. 11. Remove the latch release handle bezel. - Release the upper tab and separate the bezel from the latch release handle. 12. NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the backrest foam pad. Partially invert the backrest cover to the row of hog rings. 13. Remove all hog rings and backrest cover. - Route the safety belt webbing through the backrest cover opening. 14. NOTE: 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 Backrest Cover - Second Row, 40 Percent Seat Backrest Cover - Second Row, 40 Percent Removal and Installation 1. NOTICE: Use care when releasing the spring clips. They can fall inside the backrest frame. Remove the head restraint. - Pull the backrest cover material away from the head restraint guide to access the spring clips. - Release the 2 spring clips by pushing on the side shown. Note the spring clip position for correct installation. - Raise and remove the head restraint. 2. Position the backrest downward. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7846 3. Remove the kneeling release (cargo mode) handle. - Raise the handle to access the cable. - Detach the cable jacket from the kneeling release handle. - Release the retainers and position aside the kneeling release handle. 4. Release the lower backrest cover J-clip. 5. Position aside the backrest cover rear flap and remove the 4 pin-type retainers. 6. If equipped, disconnect the backrest heater mat electrical connector. - Release the cushion cover rear J-clip. - Disconnect the electrical connector. - Detach the electrical connector and heater mat wiring. 7. Raise the backrest and route the J-clip between the backrest and cushion. 8. NOTICE: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the seat backrest foam pad. Invert the backrest cover to the row of hog rings. - Separate the hook-and-loop strips. - If equipped, route the heater mat wiring through the backrest cover. 9. Remove the row of hog rings. 10. Continue inverting the backrest cover to the head restraint guides. 11. NOTICE: Use care when separating the head restraints and spring clips to avoid tearing or damaging the backrest cover. Pinch the head restraint guide ends to release and remove the 2 head restraint guides. 12. Remove the backrest cover. 13. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 20 Percent Seat Cushion Cover - Second Row, 20 Percent Removal and Installation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7847 NOTE: For parts identification and locations, refer to Seat - Exploded View, Second Row See: Service and Repair/Second Row Seats/Seat - Exploded View, Second Row. 1. Release the 2 backrest cover lower J-clips. 2. Remove the screw and pivot bolt cover. - Route out the attaching strap. 3. Remove the 2 pin-type retainers and lower panel. 4. Lower the backrest, release the cushion cover rear J-clip and route between the cushion and backrest. 5. Release the hook-and-loop strip and remaining cushion cover J-clips. 6. Remove the cushion foam pad and cushion cover together. 7. NOTICE: Use care when separating the seat cushion cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the seat cushion foam. Release the hook-and-loop strips and invert the cushion cover to the row of hog rings. 8. Remove all hog rings and cushion cover. 9. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 40 Percent Seat Cushion Cover - Second Row, 40 Percent Removal and Installation 1. With the seat in the E-Z entry position, release the rear J-clip and partially invert the cushion cover. 2. Release the trim cover J-clips from both sides of the cushion. 3. Release the outer and inner rear J-clips from the cushion. 4. If equipped, disconnect and detach the cushion heater mat electrical connector and heater mat wiring. 5. Latch the seat to the floor and raise the backrest. 6. Release the front J-clip from the cushion. 7. Release the 2 cushion trim cover retainers from the 2 child safety seat lower anchors and tethers for children anchors. - Pull the cushion trim cover rearward and release the 2 clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7848 8. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the seat cushion foam. Separate the hook-and-loop strips and invert the cushion trim cover to the row of hog rings. 9. Remove the row of hog rings. 10. Remove the cushion trim cover. - Route the trim cover from between the cushion and backrest. 11. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7849 Seat Cover: Service and Repair Third Row Seats Seat - Exploded View, Third Row Seat - Exploded View, Third Row Seat Backrest - 40 percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7850 Seat Cushion - 40 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7851 Seat Backrest - 60 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7852 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7853 Seat Cushion - 60 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7854 1. For additional information, refer to the procedures. Seat Backrest Cover - Third Row Seat Backrest Cover - Third Row Removal and Installation NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. NOTE: LH shown, RH similar. All seats 1. Remove the seat. Refer to Seat - Third Row See: Service and Repair/Third Row Seats/Seat Third Row. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7855 2. Remove the seat backrest. Refer to Seat Backrest - Third Row, 40 Percent See: Seat Back/Service and Repair/Removal and Replacement/Third Row Seats/Seat Backrest - Third Row, 40 Percent or Seat Backrest - Third Row, 60 Percent See: Seat Back/Service and Repair/Removal and Replacement/Third Row Seats/Seat Backrest - Third Row, 60 Percent. 3. NOTICE: Use care when releasing the spring clips. They can fall inside the backrest frame. Remove the head restraint. - Pull the trim cover material away from the head restraint guide to access the spring clips. - Release the 2 spring clips by pushing on the side shown. Note the spring clip position for correct installation. - Raise and remove the head restraint. 4. Release all backrest cover J-clips. 5. Remove all staples. LH seat 6. Release the hook-and-loop strip. 7. Remove the safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 8. Remove the safety belt guide cover. Manual fold seat 9. Remove the 2 screws and manual latch handle and cable assembly. - Note cable routing for correct installation. All seats 10. Reach up into backrest and squeeze the head restraint guide ends together to release and pull the 2 head restraint guides out. - The head restraint guides are not interchangeable. Note location for correct installation. 11. NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the backrest foam pad. Separate the hook-and-loop strips and invert the backrest cover to the row of hog rings. 12. Remove all hog rings. 13. Remove the backrest cover. - For LH seat backrest, route the safety belt webbing through the backrest cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7856 14. NOTE: 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 - Third Row Seat Cushion Cover - Third Row Removal and Installation NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. NOTE: LH shown, RH similar. 1. Remove the seat. For additional information, refer to Seat - Third Row See: Service and Repair/Third Row Seats/Seat - Third Row. 2. Raise the cushion, separate the cushion cover hook-and-loop strips and release the J-clips. 3. Remove the cushion cover and foam pad from the cushion frame. 4. NOTICE: Use care when separating the cushion cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the cushion foam pad. Separate the hook-and-loop strips and invert the cushion cover to the row of hog rings. 5. Remove all hog rings and cushion cover. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seats Seat Cushion: Service and Repair Front Seats Seat Cushion - Front Disassembly and Assembly NOTE: If a new Driver Seat Module (DSM) has been installed, all seat and power tilt column (if equipped) soft stops must be reset. If a new seat track, recline motor or power tilt column has been installed, only reset the soft stops for that component being installed new. To set the soft stops, refer to principles of operation. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Principles Of Operation NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. All seats 1. Remove the seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 2. Remove the seat cushion cover. For additional information, refer to Seat Cushion Cover - Front See: Seat Cover/Service and Repair/Front Seats/Seat Cushion Cover - Front. 3. Remove the cushion foam pad. 4. Remove the safety belt buckle and pretensioner. - Remove the tie strap. - Disconnect the 2 electrical connectors. - Remove the nut and safety belt buckle and pretensioner. To install, tighten to 55 Nm (41 lb-ft). 5. For driver seat, disconnect the seat track position sensor electrical connector and detach the wiring harness pin-type retainer. Climate controlled seat 6. Remove the cushion TED. - Detach the wiring harness and remove the TED. - Note wire harness routing for correct installation. 7. Release the 2 tabs and slide out the Dual Climate Controlled Seat Module (DCSM). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seats > Page 7861 8. NOTE: When installing a new DCSM, it is necessary to carry out Programmable Module Installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning For passenger seat, remove the DCSM. Cut and remove the wire harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. Power seat 9. If equipped, remove the DSM. - Disconnect the 4 electrical connectors. - Release the 2 tabs and slide out the DSM. 10. Disconnect the 3 seat track motor electrical connectors. - For driver seat with memory, disconnect the 3 additional motor sensor electrical connectors. 11. Remove the wire harness. - Remove the 3 wire harness bracket screws. - Remove the tie strap and release the rear wire harness bracket clip from the seat track. - Separate the electrical connectors and wire harness from the seat track. - Remove the wire harness and bracket. - For correct installation, note wire harness routing. All seats 12. For manual seat, remove the inboard and outboard seat track rails. - Remove the 6 seat track rail-to-seat track nuts from the inboard and outboard seat track rails. To install, tighten to 30 Nm (22 lb-ft). - Remove the inboard and outboard seat track rails. - Release and separate the seat track adjust handle from the seat track rails. Disconnect the spring. - Slightly bend the tab and detach the seat adjust handle from the inboard seat track rail. - Note the spring position for correct installation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seats > Page 7862 13. To assemble, reverse the disassembly procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seats > Page 7863 Seat Cushion: Service and Repair Second Row Seats Seat Cushion - Second Row, 20 Percent Disassembly and Assembly NOTE: For parts identification and locations, refer to Seat - Exploded View, Second Row See: Service and Repair/Second Row Seats/Seat - Exploded View, Second Row. 1. Remove the seat backrest. For additional information, refer to Seat Backrest - Second Row, 20 Percent See: Seat Back/Service and Repair/Removal and Replacement/Second Row Seats/Seat Backrest - Second Row, 20 Percent. 2. Remove the 2 screws and LH side shield. 3. Remove the nut and safety belt buckle. - To install, align the anti-rotation tab. To install, tighten to 55 Nm (41 lb-ft). 4. Release the cushion cover front J-clip. 5. Remove the 2 riser-to-cushion frame bolts and cushion frame. - To install, tighten to 30 Nm (22 lb-ft). 6. Release the hook-and-loop strip and remaining cushion cover J-clips. 7. Remove the cushion frame from the foam pad and cushion cover. 8. NOTICE: Use care when separating the seat cushion cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the seat cushion foam. Release the hook-and-loop strips and invert the cushion cover to the row of hog rings. 9. Remove all hog rings and cushion cover. 10. To assemble, reverse the disassembly procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seats > Page 7864 Seat Cushion: Service and Repair Third Row Seats Seat Cushion - Third Row, 40 Percent Seat Cushion - Third Row, 40 Percent Disassembly and Assembly NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. 1. Remove the seat backrest. For additional information, refer to Seat Backrest - Third Row, 40 Percent See: Seat Back/Service and Repair/Removal and Replacement/Third Row Seats/Seat Backrest - Third Row, 40 Percent. 2. Remove the inboard and outboard slide bracket-to-cushion frame nuts and slide bracket from both sides of the seat cushion. - To install, tighten to 15 Nm (133 lb-in). 3. Remove the 2 seat riser-to-cushion frame bolts and riser. - To install, tighten to 30 Nm (22 lb-ft). 4. Release the cushion cover J-clips and remove the cushion frame. 5. NOTICE: Use care when separating the cushion cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the cushion foam pad. Separate the hook-and-loop strips and invert the cushion cover to the row of hog rings. 6. Remove all hog rings and cushion cover. 7. To assemble, reverse the disassembly procedure. Seat Cushion - Third Row, 60 Percent Seat Cushion - Third Row, 60 Percent Disassembly and Assembly NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row See: Service and Repair/Third Row Seats/Seat - Exploded View, Third Row. 1. Remove the seat backrest. For additional information, refer to Seat Backrest - Third Row, 60 Percent See: Seat Back/Service and Repair/Removal and Replacement/Third Row Seats/Seat Backrest - Third Row, 60 Percent. 2. Remove the inboard and outboard slide bracket-to-cushion frame nuts and slide bracket from both sides of the seat cushion. - To install, tighten to 15 Nm (133 lb-in). 3. Remove the 2 seat riser-to-cushion frame bolts and riser. - To install, tighten to 30 Nm (22 lb-ft). 4. Release the cushion cover J-clips and remove the cushion frame. 5. NOTICE: Use care when separating the cushion cover from the hook-and-loop strip, or the hook-and-loop strip may be torn from the cushion foam pad. Separate the hook-and-loop strips and invert the cushion cover to the row of hog rings. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seats > Page 7865 6. Remove all hog rings and cushion cover. 7. To assemble, reverse the disassembly procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7870 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7871 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7872 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7873 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7875 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7876 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7877 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 Seat Heater: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 119-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 119-3 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 119-4 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 119-5 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 119-6 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Exploded View, Front Seat Heater: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Exploded View, Front > Page 7902 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Exploded View, Front > Page 7903 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Exploded View, Front > Page 7904 Seat Heater: Service and Repair Seat Backrest Seat Backrest Thermo-Electric Device Seat Backrest Thermo-Electric Device Removal and Installation 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: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. 1. With the backrest fully forward, release the seat backrest cover lower rear J-clip and unzip the 2 side zippers. 2. Remove the climate controlled seat Thermo-Electric Device (TED). - Disconnect the TED electrical connector. - Remove the scrivet. - Detach the 2 retainer clips from the backrest frame support wires. 3. To install, reverse the removal procedure. Seat Backrest Heater Mat Seat Backrest Heater Mat Removal NOTICE: Do not reinstall any heater mat after removal. The adhesive will not adhere correctly to the foam pad causing it to bunch up or shift out of place. A new heater mat must be installed. Failure to follow this instruction can result in seat component damage and system failure. 1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover Second Row, 40 Percent See: Seat Cover/Service and Repair/Second Row Seats/Seat Backrest Cover/Seat Backrest Cover - Second Row, 40 Percent. 2. Route the heater mat wiring harness from the seat. - Note harness routing for correct installation. 3. NOTICE: Do not use a razor knife or other sharp tool to separate the heater mat from the foam pad. Damage to the foam pad may result. Install a new foam pad if torn or burned. Carefully peel the backrest heater mat from the foam pad and discard. - Only a thin layer of foam should peel off with the adhesive. 4. If burned or torn, remove and discard the backrest foam pad. Installation 1. If needed, install a new backrest foam pad. 2. NOTICE: Remove all paper strips from the adhesive before applying the heater mat to the foam pad. Otherwise, damage to the seat can Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Exploded View, Front > Page 7905 occur. Install the heater mat to the foam pad. - Align the heater mat square to the seat backrest with the narrow area of the heater mat tucked into the valley of the foam pad and the wiring toward the lower edge. - Firmly apply the heater mat to the foam pad making sure it is straight and free of any wrinkles that may show through the backrest cover. 3. Route the heater mat wire harness as noted in removal. 4. Install the seat backrest cover. For additional information, refer to Seat Backrest Cover - Second Row, 40 Percent See: Seat Cover/Service and Repair/Second Row Seats/Seat Backrest Cover/Seat Backrest Cover - Second Row, 40 Percent. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Exploded View, Front > Page 7906 Seat Heater: Service and Repair Seat Cushion Seat Cushion Thermo-Electric Device Seat Cushion Thermo-Electric Device Removal and Installation NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. 1. Remove the seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. NOTE: Use care when removing the Thermo-Electric Device (TED). The U-nuts can slip into the cushion frame. Remove the seat cushion TED. - Disconnect the electrical connector and detach the wire harness. - Remove the 2 screws and TED. - For correct installation, note wire harness routing. 3. To install, reverse the removal procedure. Seat Cushion Heater Mat Seat Cushion Heater Mat Removal NOTICE: Do not reinstall any heater mat after removal. The adhesive will not adhere correctly to the foam pad causing it to bunch up or shift out of place. A new heater mat must be installed. Failure to follow this instruction can result in seat component damage and system failure. 1. Remove the seat cushion trim cover. For additional information, refer to Seat Cushion Cover Second Row, 40 Percent See: Seat Cover/Service and Repair/Second Row Seats/Seat Cushion Cover/Seat Cushion Cover - Second Row, 40 Percent. 2. Route the heater mat wiring harness from the seat. - Note harness routing for correct installation. 3. NOTICE: Do not use a razor knife or other sharp tool to separate the heater mat from the foam pad. Damage to the foam pad may result. Install a new foam pad if torn or burned. Carefully peel the cushion heater mat from the foam pad and discard. - Only a thin layer of foam should peel off with the adhesive. 4. If burned or torn, remove and discard the cushion foam pad. Installation 1. If needed, install a new cushion foam pad. 2. NOTICE: Remove all paper strips from the adhesive before applying the heater mat to the foam pad. Otherwise, damage to the seat can Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Exploded View, Front > Page 7907 occur. Install the heater mat to the foam pad. - Align the heater mat square to the seat cushion with the narrow area of the heater mat tucked into the valley of the foam pad and the wiring toward the rear edge of the seat cushion frame. - Firmly apply the heater mat to the foam pad making sure it is straight and free of any wrinkles that may show through the cushion cover. 3. Route the heater mat wire harness as noted in removal. 4. Install the seat cushion cover. For additional information, refer to Seat Cushion Cover - Second Row, 40 Percent See: Seat Cover/Service and Repair/Second Row Seats/Seat Cushion Cover/Seat Cushion Cover - Second Row, 40 Percent. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module Seat Heater Control Module: Locations Rear Heated Seat Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module > Page 7912 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Rear Heated Seat Module > Page 7913 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module Seat Heater Control Module: Diagrams Rear Heated Seat Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 7916 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 7917 Seat Heater Control Module: Diagrams Dual Climate Controlled Seat Module (DCSM) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 7918 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Rear Heated Seat Module > Page 7919 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7922 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7923 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7924 Seat Heater Control Module: Service and Repair Dual Climate Controlled Seat Module (DCSM) Dual Climate Controlled Seat Module (DCSM) Removal and Installation 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. NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. 1. When installing a new Dual Climate Controlled Seat Module (DCSM), carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Position the front passenger seat fully upward and remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. 3. Release the 2 tabs and slide out the DCSM. 4. Remove the DCSM. - Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. 5. To install, reverse the removal procedure. 6. If a new DCSM has been installed, carry out the appropriate steps in the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7925 Seat Heater Control Module: Service and Repair Heated Seat Module - Second Row Heated Seat Module - Second Row NOTE: Bottom of floor console shown. Removal and Installation 1. Remove the front floor console. 2. Disconnect the 2 heated seat module electrical connectors at the bottom of the front floor console. 3. Remove the screw and un-hook the heated seat module. 4. To install, reverse the removal procedure. 5. Carry out the auto-configuration sequence to program the heated seat module for use with a dual momentary switch. - Start the vehicle and push the low button on either heated seat switch. - Operate the heated seats, monitor the indicators and verify the system is operating correctly in high and low. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear Seat Heater Switch: Locations Heated Seat Switch, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 7930 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 7931 Seat Heater Switch: Locations Heated Seat Switch, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 7932 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Left Rear > Page 7935 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7938 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7939 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7940 Seat Heater Switch: Service and Repair Seat Control Switch - Front Seat Control Switch - Front Removal and Installation 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: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. NOTE: Driver seat shown, passenger similar. All seats 1. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Side shield with insert 2. Release the retainers and remove the insert from the side shield. - Disconnect the electrical connector(s). Side shield with cover 3. Remove the front side shield screw. 4. Remove the side shield cover. - Disconnect the electrical connector(s). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7941 All seats 5. Pull and remove the seat control switch button(s). - If equipped, remove the power recliner switch button. 6. Release the clips and remove the seat control switch. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7942 Seat Heater Switch: Service and Repair Heated Seat Switch - Second Row Heated Seat Switch - Second Row Removal and Installation 1. Release the 4 retainer clips and remove the rear cup holder. - Remove any remaining retainers from the floor console and reinstall to the cup holder before installation. 2. Remove the front floor console rear panel. - Remove the 2 screws. - Release the 6 retainer clips and separate the rear panel. - Disconnect all the electrical connectors and remove the rear panel. - Remove any remaining retainers from the floor console and reinstall to the rear cover before installation. 3. Release and remove the heated seat switch(es). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7943 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row Seat Control Switch - Third Row Removal and Installation 1. Release and remove the tray from the RH rear quarter trim panel. 2. NOTE: The LH and RH switch wiring harness electrical connectors are not interchangeable. Remove the affected seat control switch. - Release the 2 retaining tabs and detach the seat control switch from the RH rear quarter trim panel. - Pull the seat control switch through the opening and disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats Seat Latch: Service and Repair Second Row Seats Seat - Exploded View, Second Row Seat Backrest - 20 Percent Seat Cushion - 20 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats > Page 7948 Seat Backrest - 40 Percent NOTE: LH seat shown, RH similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats > Page 7949 Seat Cushion - 40 Percent Seat NOTE: LH seat shown, RH seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats > Page 7950 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats > Page 7951 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats > Page 7952 Seat Latch: Service and Repair Third Row Seats Seat - Exploded View, Third Row Seat Backrest - 40 percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats > Page 7953 Seat Cushion - 40 Percent Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats > Page 7954 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seats > Page 7955 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual Seat Track: Service and Repair Seat Track - Manual Seat Track - Manual Removal and Installation NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. 1. Remove the seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front or. 2. Remove the inboard and outboard seat track rails. - Remove the 6 seat track rail-to-seat track nuts from the inboard and outboard seat track rails. To install, tighten to 30 Nm (22 lb-ft). - Remove the inboard and outboard seat track rails. - Release and separate the seat track adjust handle from the seat track rails. Disconnect the spring. - Slightly bend the tab and detach the seat adjust handle from the inboard seat track rail. - Note the spring position for correct installation. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 7960 Seat Track: Service and Repair Seat Track - Power Seat Track - Power Removal and Installation NOTE: If a new Driver Seat Module (DSM) has been installed, all seat and power tilt column (if equipped) soft stops must be reset. If a new seat track, recline motor or power tilt column has been installed, only reset the soft stops for that component being installed new. To reset the soft stops, refer to principles of operation. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Principles Of Operation NOTE: For component identification and locations, refer to Seat - Exploded View, Front See: Service and Repair/Front Seats/Seat - Exploded View, Front. All seats 1. Remove the affected seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the 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 safety belt buckle and pretensioner. - Remove the tie strap. - Disconnect the 2 electrical connectors. - Remove the nut and safety belt buckle and pretensioner. To install, tighten to 55 Nm (41 lb-ft). 4. Release the cushion cover front and rear J-clips and rear hook-and-loop strip. Climate controlled seats 5. NOTE: Use care when removing the Thermo-Electric Device (TED). The U-nuts can slip into the cushion frame. Remove the cushion TED. - Disconnect the electrical connector and detach the wire harness. - Remove the 2 screws and TED. - For correct installation, note wire harness routing. 6. Release the 2 tabs and slide out the Dual Climate Controlled Seat Module (DCSM). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 7961 7. NOTE: When installing a new DCSM, it is necessary to carry out Programmable Module Installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning If passenger seat, remove the DCSM. Cut and remove the wiring harness tie strap. - Release the 2 locking wedges. - Disconnect the 3 electrical connectors. Driver memory seat 8. Remove the DSM. - Disconnect the 4 electrical connectors. - Release the 2 tabs and slide out the DSM. All seats 9. Remove the cushion frame, foam pad and cushion cover assembly from the seat track. - Remove the 4 cushion frame-to-seat track bolts. To install, tighten to 25 Nm (18 lb-ft). - Release the 2 cushion frame rear clips and straps from the seat track and remove the cushion frame. 10. Disconnect the 3 seat track motor electrical connectors. - For driver seat with memory, disconnect the additional 3 motor sensor electrical connectors. 11. Remove the wire harness. - Remove the 3 wire harness bracket screws. - Remove the tie strap and release the rear wire harness bracket clip from the seat track. - Separate the electrical connectors and wire harness from the seat track. - Remove the wire harness and bracket. - For correct installation, note wire harness routing. 12. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 7962 Seat Track: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 7963 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 7964 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations > Lumbar Motor, Driver Seat Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations > Lumbar Motor, Driver Seat > Page 7969 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Diagrams > Lumbar Motor, Driver Seat Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Diagrams > Lumbar Motor, Driver Seat > Page 7972 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Hood Sensor/Switch (For Alarm): Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7978 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7979 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 7983 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 7984 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 7987 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 7988 Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 7989 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Power Door Lock Switch: Locations Door Lock Switch, Passenger Side Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7994 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7995 Power Door Lock Switch: Locations Door Lock Switch, Driver Side Ford Expedition 2wd Workshop Manual (V8-5.4L (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 7996 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 7999 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 8000 Power Door Lock Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 8001 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8005 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8006 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8007 Power Mirror Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8008 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8009 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8010 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Remove the driver front door trim panel. 2. Remove the exterior mirror control switch. 1. Depress the locking tabs. 2. Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 8015 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 8016 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 8017 Power Seat Motor Position Sensor: Locations Height Sensor, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 8018 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 8019 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 8020 Power Seat Motor Position Sensor: Locations Height Sensor, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Position Sensor > Page 8021 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 8024 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 8025 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 8026 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Position Sensor > Page 8027 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 8032 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 8033 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 8034 Power Seat Switch: Locations Third Row Power-Fold Seat Switch, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 8035 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 8036 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 8037 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Power-Fold Seat Switch, Left > Page 8038 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left Power Seat Switch: Diagrams Seat Control Switch, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 8041 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 8042 Power Seat Switch: Diagrams Seat Control Switch, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 8043 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 8044 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Left > Page 8045 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left Power Seat Switch: Testing and Inspection Seat Control Switch, 10-Way - Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8048 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8049 Power Seat Switch: Testing and Inspection Seat Control Switch, 10-Way - Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8050 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8051 Power Seat Switch: Testing and Inspection Seat Control Switch, 6-Way - Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8052 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8053 Power Seat Switch: Testing and Inspection Seat Control Switch, 6-Way - Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8054 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8055 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8056 Power Seat Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8057 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8058 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8059 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8060 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8061 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8062 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8063 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8064 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8065 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8066 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, 10-Way - Left > Page 8067 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8070 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8071 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8072 Power Seat Switch: Service and Repair Memory Set Switch Memory Set Switch Removal and Installation 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: For component identification and locations, refer to Seat - Exploded View, Front See: Seats/Service and Repair/Front Seats/Seat - Exploded View, Front. All seats 1. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Driver seat side shield with insert 2. Release the retainers and remove the insert from the side shield. - Disconnect the electrical connectors. Driver seat side shield with cover 3. Remove the front side shield screw. 4. Remove the side shield cover. All seats 5. Release the clips and remove the memory SET switch. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8073 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Liftgate Pinch Strip, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Liftgate Pinch Strip, Left > Page 8078 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch Power Trunk / Liftgate Lock Switch: Locations Handle Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 8083 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 8084 Power Trunk / Liftgate Lock Switch: Locations Liftgate Glass Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Handle Release Switch > Page 8085 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch Power Trunk / Liftgate Lock Switch: Diagrams Handle Release Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 8088 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Handle Release Switch > Page 8089 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 8090 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Release Switch Expedition Navigator Removal and Installation All vehicles 1. Remove the liftgate trim panel. - Position the water shield aside. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 8091 Expedition 2. Remove the 2 nuts and the liftgate release handle. - Disconnect the electrical connector. - To install, tighten to 6 Nm (53 lb-in). 3. Remove the liftgate release switch. - Disconnect the electrical connector. Navigator 4. Remove the liftgate parking lamps. 5. Remove the 6 nuts and the license plate housing. - Disconnect the electrical connector. - To install, tighten to 5 Nm (44 lb-in). 6. Remove the 2 nuts and the liftgate release switch housing. - Disconnect the electrical connector. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the liftgate release switch. - Disconnect the electrical connector. All vehicles 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear Seat Heater Switch: Locations Heated Seat Switch, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 8096 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 8097 Seat Heater Switch: Locations Heated Seat Switch, Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Heated Seat Switch, Left Rear > Page 8098 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Left Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Heated Seat Switch, Left Rear > Page 8101 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Seat Backrest - Front, 40 Percent NOTE: Driver power seat backrest shown, passenger and manual similar. Seat Cushion - Front, 40 Percent NOTE: Driver memory seat shown, driver and passenger power seat similar. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 8104 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 8105 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 8106 Seat Heater Switch: Service and Repair Seat Control Switch - Front Seat Control Switch - Front Removal and Installation 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: For component identification and locations, refer to Seat - Exploded View, Front See: Seats/Service and Repair/Front Seats/Seat - Exploded View, Front. NOTE: Driver seat shown, passenger similar. All seats 1. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid damaging it. Remove the front seat cushion panel shield. - Release the upper retaining clips working from the outboard side and then release the lower retaining clips. Side shield with insert 2. Release the retainers and remove the insert from the side shield. - Disconnect the electrical connector(s). Side shield with cover 3. Remove the front side shield screw. 4. Remove the side shield cover. - Disconnect the electrical connector(s). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 8107 All seats 5. Pull and remove the seat control switch button(s). - If equipped, remove the power recliner switch button. 6. Release the clips and remove the seat control switch. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 8108 Seat Heater Switch: Service and Repair Heated Seat Switch - Second Row Heated Seat Switch - Second Row Removal and Installation 1. Release the 4 retainer clips and remove the rear cup holder. - Remove any remaining retainers from the floor console and reinstall to the cup holder before installation. 2. Remove the front floor console rear panel. - Remove the 2 screws. - Release the 6 retainer clips and separate the rear panel. - Disconnect all the electrical connectors and remove the rear panel. - Remove any remaining retainers from the floor console and reinstall to the rear cover before installation. 3. Release and remove the heated seat switch(es). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 8109 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row Seat Control Switch - Third Row Removal and Installation 1. Release and remove the tray from the RH rear quarter trim panel. 2. NOTE: The LH and RH switch wiring harness electrical connectors are not interchangeable. Remove the affected seat control switch. - Release the 2 retaining tabs and detach the seat control switch from the RH rear quarter trim panel. - Pull the seat control switch through the opening and disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 8113 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection Sunroof / Moonroof Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 8117 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch Trunk / Liftgate Switch: Locations Liftgate Rear Control Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 8122 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 8123 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 8124 Trunk / Liftgate Switch: Locations Power Liftgate/Traction Control/Hazard Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Rear Control Switch > Page 8125 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Rear Control Switch > Page 8128 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Position Sensor > Component Information > Service and Repair Trunk / Liftgate Position Sensor: Service and Repair Pinch Strip Switch Removal and Installation NOTE: Left side shown, right side similar. 1. Remove the brake light. - Remove the screws. 2. Disconnect the pinch strip electrical connector. 3. Remove the pinch strip. 1. Remove the pin-type retainers. 2. Remove the grommet and route the harness out of the vehicle. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Position Sensor > Component Information > Service and Repair > Page 8132 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. Insulation is installed: See: Sound Deadeners and Insulators - under the roof. - above and below the instrument panel. - at the cowl sides. - over the transmission tunnel. - over the floorpan areas. - inside the quarter panels. It has heat-bondable mastic deadeners for improved NVH characteristics (Navigator). Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 8137 Sound Proofing / Insulation: Description and Operation Sound Deadeners and Insulators Sound Deadeners and Insulators 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 can cause the mastic material to burn. NOTICE: 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. NOTE: To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be replaced with the correct service replacement component. 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Removal and Installation Both sides 1. Remove the windshield wipers. LH side 2. Remove the pin-type retainer and lift the LH cowl trim panel to release the 3 underside pushpin retainers that are attached to the cowl trim panel. - Disconnect the windshield washer tube. RH side 3. Remove the pin-type retainer and lift the RH cowl trim panel to release the 2 underside pushpin retainers that are attached to the cowl trim panel. - Disconnect the windshield washer tube. Both sides 4. To install, reverse the removal procedure. 5. If necessary, adjust the windshield wiper arms. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8148 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation NOTE: The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Windows and Glass/Windows/Service and Repair. 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 inside glass weatherstrip. 3. Remove the front door glass channel bolt and front door glass top run. - To install, tighten to 11 Nm (97 lb-in). 4. To install, reverse the removal procedure. - The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Windows and Glass/Windows/Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 rear door glass channel bolt. - To install, tighten to 11 Nm (97 lb-in). 3. Remove the rear door glass top run. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear > Page 8153 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: Customer Interest Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash > Page 8162 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash > Page 8163 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 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 8169 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 8170 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 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 8171 Sunroof / Moonroof Weatherstrip: Service and Repair Roof Opening Panel Weatherstrip Removal NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when a new roof opening panel assembly has been installed. For additional information, refer to Roof Opening Panel Motor Initialization See: Roof and Associated Components/Sunroof / Moonroof/Testing and Inspection/Programming and Relearning. 1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel Glass See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Roof Opening Panel Glass. 2. Place roof opening panel, topside up, on a worktable. Take care to support the glass assembly from below to prevent damaging the mounting tabs. 3. Remove the old roof opening panel weatherstrip by pulling up on the weatherstrip. Installation 1. Place a new weatherstrip into position on the glass assembly, with the splice (seam) on the passenger side. 2. Starting with the corners, push the weatherstrip into position. Continue pushing the weatherstrip into position around the glass assembly until complete. Use a plastic or rubber hammer if necessary. 3. Install the roof opening panel. For additional information, refer to Roof Opening Panel Glass See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Roof Opening Panel Glass. 4. Align the roof panel. For additional information, refer to Roof Opening Panel Alignment See: Roof and Associated Components/Sunroof / Moonroof/Adjustments. 5. Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Roof and Associated Components/Sunroof / Moonroof/Testing and Inspection/Programming and Relearning. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8176 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8177 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 8180 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair Speed Control Switch Expedition Navigator Removal and Installation Expedition 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 8187 - Disconnect the electrical connector. Navigator 2. Remove the driver air bag module. For additional information, refer to Air Bag Systems. 3. Remove the 2 screws and the steering wheel controls bezel. 4. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8192 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8193 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 8196 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition Navigator Removal and Installation Expedition 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 8203 - Disconnect the electrical connector. Navigator 2. Remove the driver air bag module. For additional information, refer to Air Bag Systems. 3. Remove the 2 screws and the steering wheel controls bezel. 4. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8212 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8213 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8214 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8215 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8216 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8217 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8218 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8219 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8220 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8221 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8222 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8223 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8224 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8225 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8226 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8227 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8228 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8229 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8230 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8231 44-2 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 8235 Clock: Description and Operation Clock The stand-alone electric analog clock, available in the Navigator only, is centrally located on the instrument panel and displays time in a 12-hour format. The clock is backlit when the headlamps and parking lamps are on. The Expedition clock is integrated into the radio. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Clock: Initial Inspection and Diagnostic Overview Special Tools Used With Diagnostics Clock Inspection And Verification Clock Inspection and Verification NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). 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. 4. If the fault is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8238 Clock: Symptom Related Diagnostic Procedures Clock Symptom Chart Symptom Chart Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8239 Clock: Pinpoint Tests Clock Pinpoint Tests Pinpoint Tests A: The Clock Is Inoperative Refer to Wiring Diagram Set 44, Horn/Cigar Lighter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The clock receives battery voltage from the Smart Junction Box (SJB) through circuit SBP14 (BN/RD). Ground for the clock is supplied through circuit GD138 (BK/WH). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Clock - SJB PINPOINT TEST A: THE CLOCK IS INOPERATIVE 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 CHECK CIRCUIT SBP14 (BN/RD) FOR VOLTAGE - Ignition OFF. - Disconnect: Clock C2016. - Measure the voltage between the clock C2016-6, circuit SBP14 (BN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to A2. No VERIFY the SJB fuse 14 (10A) is OK. If OK, GO to A3. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- A2 CHECK CIRCUIT GD138 (BK/WH) FOR AN OPEN - Disconnect: Negative Battery Cable. - Measure the resistance between the clock C2016-5, circuit GD138 (BK/WH), harness side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8240 - Is the resistance less than 5 ohms? Yes INSTALL a new clock. REFER to Clock See: Service and Repair. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- A3 CHECK CIRCUIT SBP14 (BN/RD) FOR AN OPEN - Disconnect: SJB C2280b. - Measure the resistance between the SJB C2280b-4, circuit SBP14 (BN/RD), harness side and the clock C2016-6, circuit SBP14 (BN/RD), harness side. - Is the resistance less than 5 ohms? Yes GO to A4. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- A4 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. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 8241 Clock: Service and Repair Clock Removal and Installation 1. Remove the upper instrument panel center finish panel. 2. Release the 3 retaining clips and remove the clock from the upper instrument panel center finish panel. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment - With Message Center Compass: Service and Repair Compass Zone Adjustment - With Message Center Compass Zone Adjustment - With Message Center 1. Determine which magnetic zone you are in for your geographic location. 2. Start the engine. 3. Press the message center SETUP button until RESET FOR ZONE SETTING is displayed. 4. Press and release the RESET button until ZONE XX RESET = CHANGE is displayed. 5. NOTE: The zone selection increases with each subsequent button press with a range of zones from 1 to 15 scrolling back to the beginning. Press and release the RESET button until the desired zone appears in the message center display. 6. To exit the zone setting mode and lock in the changes, press and release either the RESET or SETUP button or simply wait 4 seconds and the message center locks in the zone. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment - With Message Center > Page 8246 Compass: Service and Repair Compass Zone Adjustment - Without Message Center Compass Zone Adjustment - Without Message Center 1. Determine which magnetic zone you are in for your geographic location. 2. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 3. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 4. Press and release the SELECT/RESET button to scroll through the system check displays until the message center displays COMPASS ZONE XX is displayed. 5. Press and hold the SELECT/RESET button for approximately 2 seconds to enter the compass zone adjustment mode. 6. NOTE: The zone selection increases with each subsequent button press with a range of zones from 1 to 15 scrolling back to the beginning. Press and release the SELECT/RESET button until the desired zone number appears. 7. Release the SELECT/RESET button and allow the setup timer to expire to exit the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment - With Message Center > Page 8247 Compass: Service and Repair Compass Calibration - With Message Center Compass Calibration - With Message Center 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (heated rear window, heater, A/C, map lamps, wiper, etc.) and make sure all the doors are closed. Start the vehicle. 2. Press the message center SETUP button until RESET FOR CALIBRATION is displayed. 3. NOTE: The message center displays CIRCLE SLOWLY TO CALIBRATE in the calibration function. Press the RESET control button to start the compass calibration function. 4. NOTE: This step may require up to 5 circles to complete the calibration. NOTE: If the RESET button is pressed during the calibration or 3 minutes has elapsed since the beginning of the calibration without driving the vehicle, the message center reverts back to normal operation and the INFO displays CAL until a successful calibration is carried out. Slowly drive the vehicle in a circle less than 5 km/h (3 mph) until the CIRCLE SLOWLY TO CALIBRATE display changes to CALIBRATION COMPLETED. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment - With Message Center > Page 8248 Compass: Service and Repair Compass Calibration - Without Message Center Compass Calibration - Without Message Center 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (heated rear window, heater, A/C, map lamps, wiper, etc.) and make sure all the doors are closed. Start the vehicle. 2. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 3. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 4. Press and release the SELECT/RESET button to scroll through the system check displays until the message center displays RESET FOR CALIBRATION is displayed. 5. Press and hold the SELECT/RESET button for approximately 2 seconds to enter the compass zone adjustment mode. 6. Press and hold the SELECT/RESET button until the message center displays CIRCLE SLOWLY TO CALIBRATE is displayed. 7. NOTE: This step may require up to 5 circles to complete the calibration. NOTE: If the RESET button is pressed during the calibration or 3 minutes has elapsed since the beginning of the calibration without driving the vehicle, the message center reverts back to normal operation and the INFO displays CAL until a successful calibration is carried out. Slowly drive the vehicle in a circle less than 5 km/h (3 mph) until the CIRCLE SLOWLY TO CALIBRATE display changes to CALIBRATION COMPLETED. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 switch 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 portion 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. Make sure that all SRS components are connected. 2. Turn the ignition switch from OFF to ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8254 3. Install RCM fuse 32 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will illuminate 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. The flashing might not occur until approximately 30 seconds after the ignition 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 a 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 using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8255 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 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: 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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 portion 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. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column to allow for steering column upper and lower shroud removal. 9. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to the left from the straight-ahead position to access the driver air bag module wire clips and to prevent damage to the steering column multi-function switch. Failure to follow this instruction may result in component damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8256 Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position) as shown. 10. Remove the lower steering column opening cover. - Remove the 3 screws. - Pull out to release the top retainers. - Remove the lower steering column opening cover. If equipped, disconnect the adjustable pedals switch connector. 11. If equipped, remove the screw and steering column manual tilt lever. 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 15. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel. Failure to follow this instruction may result in component damage and/or system failure. NOTE: Steering wheel is removed for clarity. The rear of the steering wheel is shown. NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8257 16. NOTE: Once the driver air bag module is removed, note the position of the 2 driver air bag module locator pins on the steering wheel for installation. Disconnect the driver air bag module and horn switch electrical connectors and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight-ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door to allow access to the passenger air bag electrical connector. - If equipped, disconnect the glove compartment door dampener. 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat. The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical. 21. Release the RH second row safety belt retractor D-ring cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8258 22. Remove the bolt and the RH second row safety belt retractor D-ring. 23. Remove the cover and the RH C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the RH C-pillar trim panel. 25. Disconnect the RH safety canopy module electrical connector. 26. Release the LH second row safety belt retractor D-ring cover. 27. Remove the bolt and the LH second row safety belt retractor D-ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8259 28. Remove the cover and the LH C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver C-pillar trim panel. 30. Disconnect the LH safety canopy module electrical connector. 31. NOTE: There are 2 similar connectors under the driver seat. The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the Smart Junction Box (SJB). 33. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 32 (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 install the driver front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8260 4. Connect the LH safety canopy module electrical connector. 5. Install the LH C-pillar trim panel and attach the rear door weatherstrip. 6. Install the LH C-pillar trim panel nut and cover. 7. Install the LH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the LH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the RH safety canopy module electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8261 10. Install the RH C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger C-pillar trim panel nut and cover. 12. Install the RH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 13. Attach the RH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Extract and retract the safety belt between the full extension and stowed positions. - If excessive effort or binding is present, install a new safety belt buckle retractor and tongue assembly as necessary. For additional information, refer to Seat Belt Systems. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8262 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. NOTICE: The clockspring 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 horn switch and 2 driver air bag module electrical connectors. 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. NOTE: Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. 23. If equipped, install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. If equipped, connect the adjustable pedals switch connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8263 25. Install the lower steering column opening cover and 3 screws. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 32 (10A) to the SJB and install the cover. 28. 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. 29. 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 air bag SRS fault is present, the air bag warning indicator will either: - fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate 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 will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the RCM using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Navigator shown, Expedition similar. Removal and Installation 1. Remove the Instrument Cluster (IC) finish panel. 2. Press the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8271 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8272 Door Switch: Locations Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8273 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8274 Door Switch: Locations Door Ajar Switch, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8275 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8278 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8279 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8280 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 8281 Door Switch: Service and Repair Door Ajar Switch NOTE: LH front door latch shown, others similar. Removal and Installation 1. Remove the 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 or Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations Driver/Vehicle Information Display: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8285 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8286 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Oil Life Reset - Message Center Cluster Message Center Configuration Oil Life Reset - Message Center Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset - Base Instrument Cluster (IC) Message Center Configuration Oil Life Reset - Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value - Message Center Cluster Message Center Configuration Oil Life Start Value - Message Center Cluster NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value - Base Instrument Cluster (IC) Message Center Configuration Oil Life Start Value - Base Instrument Cluster (IC) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 8289 NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 8290 Driver/Vehicle Information Display: Removal and Replacement Message Center Switch Expedition Navigator Removal and Installation Expedition 1. Pull the instrument panel center finish panel straight out to release the retaining clips. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 8291 Navigator 2. NOTE: The transmission selector lever bezel is held in place by 4 tabs that are located in the shifter assembly. Remove the transmission selector lever bezel. 3. Open the floor console compartment door and pull the floor console finish panel straight up to release the retainer clips. 4. Remove the 2 screws and pull the instrument panel center finish panel straight out to release the retainer clips. - Position the instrument panel center finish panel aside. All vehicles 5. Disconnect the electrical connectors. 6. Press the 4 retaining tabs and remove the message center switch from the center instrument panel finish panel. 7. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: Customer Interest Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 8303 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 8309 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 8315 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 8316 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 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 8322 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 8323 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 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module Fuel Gauge Sender: Locations Fuel Pump Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 8326 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 8327 Fuel Gauge Sender: Locations Fuel Pump (FP) Control Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 8328 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 8329 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 8332 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 8335 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 8336 Fuel Gauge Sender: Service and Repair Fuel Pump Module Fuel Pump Module 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 8337 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. All fuel tanks 1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank. 127L (33.5 gal) fuel tank 2. Remove the 4 nuts and the Fuel Pump (FP) module cover. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the return fuel tube-to-FP module quick connect coupling. All fuel tanks 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. 5. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring. 106L (28 gal) fuel tank 6. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 8338 Remove the FP and FP O-ring seal. If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange. - Discard the FP O-ring seal. 127L (33.5 gal) fuel tank 7. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: Note the location of the FP alignment tabs. Remove the FP module assembly. Remove and discard the O-ring seal. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 switch 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 portion 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. Make sure that all SRS components are connected. 2. Turn the ignition switch from OFF to ON. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8344 3. Install RCM fuse 32 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition from ON to OFF. Wait 10 seconds, then turn the back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will illuminate 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. The flashing might not occur until approximately 30 seconds after the ignition 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 a 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 using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8345 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 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: 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 OFF. 3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM fuse 32 (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 portion 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. 7. Make sure the road wheels are in the straight-ahead position. 8. Center the tilt steering column to allow for steering column upper and lower shroud removal. 9. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to the left from the straight-ahead position to access the driver air bag module wire clips and to prevent damage to the steering column multi-function switch. Failure to follow this instruction may result in component damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8346 Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position) as shown. 10. Remove the lower steering column opening cover. - Remove the 3 screws. - Pull out to release the top retainers. - Remove the lower steering column opening cover. If equipped, disconnect the adjustable pedals switch connector. 11. If equipped, remove the screw and steering column manual tilt lever. 12. Remove the 3 steering column lower shroud screws. 13. Release the clips and remove the steering column upper shroud. 14. Remove the steering column lower shroud. - If equipped, disconnect the power tilt steering column switch located on the lower shroud. 15. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of the 3 steering wheel hooks before removing the driver air bag module from the steering wheel. Failure to follow this instruction may result in component damage and/or system failure. NOTE: Steering wheel is removed for clarity. The rear of the steering wheel is shown. NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag module wire clips attach to the steering wheel hooks. Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the steering wheel hooks. Access the 3 driver air bag module wire clips through the back of the steering wheel cover and push the wire clips toward the center of the steering wheel to release. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8347 16. NOTE: Once the driver air bag module is removed, note the position of the 2 driver air bag module locator pins on the steering wheel for installation. Disconnect the driver air bag module and horn switch electrical connectors and remove the driver air bag module. 17. Turn the steering wheel so the top of the wheel is back in the straight-ahead position (the 12 o'clock position). 18. Open and lower the glove compartment door to allow access to the passenger air bag electrical connector. - If equipped, disconnect the glove compartment door dampener. 19. Disconnect the passenger air bag module electrical connector. 20. NOTE: There are 2 similar connectors under the passenger seat. The passenger seat side air bag module electrical connector is located toward the seat outboard position. Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag module electrical. 21. Release the RH second row safety belt retractor D-ring cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8348 22. Remove the bolt and the RH second row safety belt retractor D-ring. 23. Remove the cover and the RH C-pillar trim panel nut. 24. Release the rear door weatherstrip and remove the RH C-pillar trim panel. 25. Disconnect the RH safety canopy module electrical connector. 26. Release the LH second row safety belt retractor D-ring cover. 27. Remove the bolt and the LH second row safety belt retractor D-ring. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8349 28. Remove the cover and the LH C-pillar trim panel nut. 29. Release the rear door weatherstrip and remove the driver C-pillar trim panel. 30. Disconnect the LH safety canopy module electrical connector. 31. NOTE: There are 2 similar connectors under the driver seat. The driver seat side air bag module electrical connector is located toward the seat outboard position. Remove the driver front seat cushion panel shield and disconnect the driver seat side air bag module electrical connector. 32. Install the RCM fuse 32 (10A) to the Smart Junction Box (SJB). 33. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 32 (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 install the driver front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8350 4. Connect the LH safety canopy module electrical connector. 5. Install the LH C-pillar trim panel and attach the rear door weatherstrip. 6. Install the LH C-pillar trim panel nut and cover. 7. Install the LH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 8. Attach the LH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the RH safety canopy module electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8351 10. Install the RH C-pillar trim panel and attach the rear door weatherstrip. 11. Install the passenger C-pillar trim panel nut and cover. 12. Install the RH second row safety belt retractor D-ring and bolt. - Tighten to 40 Nm (30 lb-ft). 13. Attach the RH second row safety belt retractor D-ring cover. - Verify the safety belt retractor operates without excessive effort or binding. Extract and retract the safety belt between the full extension and stowed positions. - If excessive effort or binding is present, install a new safety belt buckle retractor and tongue assembly as necessary. For additional information, refer to Seat Belt Systems. 14. Connect the passenger seat side air bag module electrical connector and install the passenger front seat cushion panel shield. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8352 15. Connect the passenger air bag module electrical connector. 16. Close the glove compartment door. - If equipped, connect the glove compartment door dampener. 17. NOTICE: The clockspring 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 horn switch and 2 driver air bag module electrical connectors. 18. Position the driver air bag module to the steering wheel, lining up the locator pins. 19. NOTE: Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to the steering wheel. NOTE: Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged. Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire clips to the steering wheel hooks. - Check the driver air bag module trim cover to the steering wheel for an even gap clearance and correct movement. 20. Install the steering column lower shroud. - If equipped, connect the power tilt steering column switch located on the lower shroud. 21. Install the steering column upper shroud. 22. Install the 3 steering column lower shroud screws. 23. If equipped, install the steering column manual tilt lever and screw. - Tighten to 6 Nm (53 lb-in). 24. If equipped, connect the adjustable pedals switch connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8353 25. Install the lower steering column opening cover and 3 screws. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 32 (10A) to the SJB and install the cover. 28. 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. 29. 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 air bag SRS fault is present, the air bag warning indicator will either: - fail to light. - remain lit continuously. - flash. The air bag warning indicator may not illuminate 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 will need to be repaired before diagnosis can continue. Clear all continuous memory DTCs from the RCM using a scan tool. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Message Center Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value Message Center Cluster NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 8358 Maintenance Required Lamp/Indicator: Reset Procedure Oil Life Reset - Message Center Cluster Message Center Configuration Oil Life Reset - Message Center Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. Press and release the SETUP button to exit the procedure. Oil Life Reset - Base Instrument Cluster (IC) Message Center Configuration Oil Life Reset - Base Instrument Cluster (IC) NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press and release the reset button to exit the procedure. Oil Life Start Value - Message Center Cluster Message Center Configuration Oil Life Start Value - Message Center Cluster NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. NOTE: The XX's in the message center displays below represent a numeric value. For example, the message center may display OIL LIFE = 80%. 1. Press and release the SETUP button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 2. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 3. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Press the RESET button once for each 10% reduction below the default 100% until the message center displays OIL LIFE SET TO XX%. 4. Press and release the SETUP button to exit the procedure. Oil Life Start Value - Base Instrument Cluster (IC) Message Center Configuration Oil Life Start Value - Base Instrument Cluster (IC) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 8359 NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). NOTE: The oil life start value is used to increase or decrease the starting point of the oil life. The value can be changed back to the maximum of approximately 12,000 km (7,500 miles) if the value was previously changed or lowered by 10% increments down to 10%. 1. Press and release the reset button to scroll through the information displays until the message center displays HOLD RESET FOR SETUP MENU. 2. Press and hold the reset button for approximately 2 seconds until the message center displays HOLD RESET FOR SYSTEM CHECK. 3. Press and release the reset button until the message center displays OIL LIFE = XXX% HOLD RESET = NEW. 4. Press and hold the RESET button for 2 seconds and release when the message center displays OIL LIFE SET TO 100%. 5. Press the RESET button to lower 10% from the default 100% until the message center displays OIL LIFE SET TO XX%. 6. NOTE: The oil life start value can be lowered from 100% to 10% in 10% increments then the value starts again at 100%. Repeat steps 2-5 for each desired 10% reduction. 7. Press and release the reset button to exit the procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Oil Life An oil change is required whenever indicated by the message center. USE ONLY RECOMMENDED ENGINE OILS. To reset the oil monitoring system to 100% after each oil change ( approximately 7,500 miles ( 12,000 km ) or 12 months ) perform the following: 1. Press and release the SETUP control to display "OIL LIFE = XXX% HOLD RESET = NEW". 2. Press and hold the RESET stem for 2 seconds and release. Oil life is set to XX% and "OIL LIFE SET TO XX%" is displayed. Note: Oil Life Start Value of 100% equals 7,500 miles (12,070 km) or 6 months. For example, setting Oil Life Start Value to 60% sets the Oil Life Start Value to 3,000 miles (4,828 km) and 120 days. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 8369 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 8370 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector. 3. Remove the EOP switch. - To install, tighten to 18 Nm (159 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Description and Operation Outside Temperature Display: Description and Operation Climate Control System External Temperature Display The external temperature is displayed when the EXT button is pressed. While the actual external temperature can vary continuously, the value that is displayed will update at a specific rate depending on whether or not the engine is "hot" and whether or not the vehicle is moving. When the external temperature is rising, the display will updated slowly. Updates (when the actual external temperature is higher than currently displayed value) will be limited to 0.55°C (1°F) every 20 seconds while the vehicle is moving at 40 kph (25 mph) for more than 90 seconds OR 0.55°C (1°F) every 20 minutes if the vehicle is not moving at this speed. This is to prevent the heat from the engine compartment from affecting the accuracy of the display. When the external temperature is dropping, the display will update quickly. Updates (when the actual external temperature is lower than currently displayed value) will only be limited to 0.55°C (1°F) every 2 seconds (regardless of vehicle speed), consequently the display will essentially follow the drop experienced by the external temperature thermistor. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams > Parking Aid Speaker Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams > Parking Aid Speaker Front > Page 8378 Parking Assist Warning Indicator: Diagrams Parking Aid Speaker Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams > Page 8379 Parking Assist Warning Indicator: Service and Repair Parking Aid Speaker - Expedition Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the bolt and the speaker and bracket assembly. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8383 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8384 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Service and Repair Seat Belt Reminder Buzzer: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation 1. Set the parking brake. 2. Place the transmission in PARK (P). 3. Turn the ignition switch to the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and passenger safety belts. Deactivating/Activating 1. Turn the ignition switch to the RUN 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 or the procedure must be repeated. Buckle then unbuckle the safety belt 9 times, ending with the safety belt unbuckled. 4. NOTE: After Step 3, the safety belt warning indicator lamp illuminates for 3 seconds. Within 10 seconds of the safety belt warning indicator turning on, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature 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 if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by a second series of 4 flashes per second for 3 seconds. 5. After confirmation, the deactivation/activation procedure is complete. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Service and Repair Seat Belt Reminder Lamp: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation 1. Set the parking brake. 2. Place the transmission in PARK (P). 3. Turn the ignition switch to the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and passenger safety belts. Deactivating/Activating 1. Turn the ignition switch to the RUN 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 or the procedure must be repeated. Buckle then unbuckle the safety belt 9 times, ending with the safety belt unbuckled. 4. NOTE: After Step 3, the safety belt warning indicator lamp illuminates for 3 seconds. Within 10 seconds of the safety belt warning indicator turning on, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature 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 if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by a second series of 4 flashes per second for 3 seconds. 5. After confirmation, the deactivation/activation procedure is complete. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Navigator shown, Expedition similar. Removal and Installation 1. Remove the Instrument Cluster (IC) finish panel. 2. Press the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Rear > Page 8399 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Rear > Page 8400 Door Switch: Locations Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Rear > Page 8401 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Rear > Page 8402 Door Switch: Locations Door Ajar Switch, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Rear > Page 8403 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8406 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8407 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8408 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 8409 Door Switch: Service and Repair Door Ajar Switch NOTE: LH front door latch shown, others similar. Removal and Installation 1. Remove the 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 or Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: Customer Interest Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 8418 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Lower Than Expected Fuel Fill Capacity TSB 09-11-7 06/15/09 LONG WHEEL BASE (LWB), LOWER THAN EXPECTED FUEL FILL CAPACITY - BUILT BEFORE 4/10/2009 FORD: 2007-2009 Expedition LINCOLN: 2007-2009 Navigator ISSUE Some 2007-2009 Expedition and Navigator long wheel base (LWB) vehicles built before 4/10/2009, may encounter the amount of fuel needed to fill the fuel tank may be lower than expected. This may be encountered when the distance to empty (DIE) states 50 miles or lower to empty, or the fuel gauge reads lower than 1/8 tank of fuel prior to refueling. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ask the customer the following questions. 1. Does the customer refill the fuel tank with the engine off? a. No - Retest the vehicle with engine off before proceeding, if concern does not occur, this procedure does not apply. b. Yes - Go to Step 2. NOTE SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75. 2. Does the customer refill the fuel tank until 1 to 3 gas pump automatic shutoffs? a. Yes - Go to Step 3. b. No - Retest the vehicle using the gasoline pump automatic shutoff function before proceeding, if concern does not occur, this procedure does not apply. 3. Replace the fuel delivery module (FDM) using the Workshop Manual, Section 310-01 with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange. 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 091107A 2007-2009 Expedition, 1.8 Hrs. Navigator: Replace The Fuel Delivery Module (Do Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 09-11-7 > Jun > 09 > Fuel System - Lower Than Expected Fuel Fill Capacity > Page 8424 Not Use With 9002A, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9H307 42 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module Fuel Gauge Sender: Locations Fuel Pump Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 8427 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 8428 Fuel Gauge Sender: Locations Fuel Pump (FP) Control Module Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 8429 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 8430 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 8433 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 8436 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 8437 Fuel Gauge Sender: Service and Repair Fuel Pump Module Fuel Pump Module 106L (28 Gal) Fuel Tank 127L (33.5 Gal) Fuel Tank Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 8438 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. All fuel tanks 1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank. 127L (33.5 gal) fuel tank 2. Remove the 4 nuts and the Fuel Pump (FP) module cover. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the return fuel tube-to-FP module quick connect coupling. All fuel tanks 4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. 5. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring. 106L (28 gal) fuel tank 6. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 8439 Remove the FP and FP O-ring seal. If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange. - Discard the FP O-ring seal. 127L (33.5 gal) fuel tank 7. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor. NOTE: Note the location of the FP alignment tabs. Remove the FP module assembly. Remove and discard the O-ring seal. All fuel tanks 8. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8443 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8444 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair Selector Lever Indicator Bulb Removal and Installation 1. Remove the selector lever assembly. 2. Release the 4 tabs on the selector lever bezel and lift the selector lever bezel up to the selector lever knob. 3. Remove the bulb retainers from the bezel and replace the bulb(s) as necessary. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 8453 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 Expedition 2wd Workshop Manual (V8-5.4L (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 8454 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 8457 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 Expedition 2wd Workshop Manual (V8-5.4L (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 8458 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 Expedition 2wd Workshop Manual (V8-5.4L (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 8459 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 Expedition 2wd Workshop Manual (V8-5.4L (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 8460 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 Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair Light Sensor NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Using a suitable tool (such as a pocket screwdriver), remove the light sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 Brake Lamp: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 90-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 90-3 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 90-4 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 Expedition 2wd Workshop Manual (V8-5.4L (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 and the high mounted stoplamp. 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, the 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. The next time a request activates a circuit 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 total 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 self-test, then the Clear DTC operation on the scan tool as long as the fault itself has been corrected. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8505 cannot be cleared and the module must be replaced. The SJB FET protected output circuits for the stoplamp system are the LH rear stop/turn lamp output and the RH rear stop/turn lamp output circuits. 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 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 the 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8506 Brake Lamp: Symptom Related Diagnostic Procedures Stoplamps Symptom Chart Symptom Chart Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8507 Brake Lamp: Pinpoint Tests Pinpoint Test I: All The Stoplamps Are Inoperative Stoplamps Pinpoint Tests Pinpoint Test I: 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 SBB43 (BU/RD) from the Battery Junction Box (BJB). When the brake pedal is applied, the stoplamp switch routes voltage to the Smart Junction Box (SJB) and the high mounted stoplamp through circuit CLS17 (YE/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Stoplamp switch PINPOINT TEST I: 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. ------------------------------------------------- I1 CHECK CIRCUIT SBB43 (BU/RD) FOR AN OPEN - Ignition OFF. - Disconnect: Stoplamp Switch C278. - Measure the voltage between the stoplamp switch C278-1, circuit SBB43 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to I2. No VERIFY the BJB fuse 43 (15A) is OK. If OK, REPAIR circuit SBB43 (BU/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- I2 BYPASS THE STOPLAMP SWITCH - Connect a fused jumper wire between the stoplamp switch C278-1, circuit SBB43 (BU/RD), harness side and the stoplamp switch C278-4, circuit CLS17 (YE/GY), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8508 - Are the stoplamps illuminated? 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. REPAIR circuit CLS17 (YE/GY) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test J: One Or More Stoplamps Are Inoperative Stoplamps Pinpoint Tests Pinpoint Test J: 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 When the brake pedal is applied, the stoplamp switch routes voltage to the Smart Junction Box (SJB) and the high mounted stoplamp through circuit CLS17 (YE/GY). When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH rear stoplamp and trailer tow LH stop/turn relay through circuit CLS18 (GY/BN) and the RH rear stoplamp and trailer tow RH stop/turn relay through circuit CLS19 (VT/OG). Ground for the LH rear stoplamp is provided through circuit GD149 (BK/GY) and the RH rear stoplamp through circuit GD150 (BK/WH). Ground for the high mounted stoplamp is provided through circuit GD150 (BK/WH). B2044-B2047 This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow stop/turn relay - Bulb holder - High mounted stoplamp - SJB PINPOINT TEST J: ONE OR MORE 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. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8509 J1 DETERMINE THE INOPERATIVE STOPLAMP - Ignition OFF. - Apply the brake pedal and observe the stoplamps. - Are all the stoplamps inoperative? Yes Go To Pinpoint Test I See: Pinpoint Test I: All The Stoplamps Are Inoperative No For the high mounted stoplamp, GO to J2. If both sides (LH and RH rear stoplamps) are inoperative, VERIFY the SJB fuse 6 (20A) is OK. If OK, GO to J4. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. If only one side (the LH or RH rear stoplamp) is inoperative, GO to J5. ------------------------------------------------- J2 CHECK FOR VOLTAGE TO THE HIGH MOUNTED STOPLAMP - Disconnect: High Mounted Stoplamp C475. - While applying the brake pedal, measure the voltage between the high mounted stoplamp C475-1, circuit CLS17 (YE/GY), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to J3. No REPAIR circuit CLS17 (YE/GY) for an open. TEST the system for normal operation. ------------------------------------------------- J3 CHECK FOR VOLTAGE TO THE HIGH MOUNTED STOPLAMP USING THE CONNECTOR GROUND - While applying the brake pedal, measure the voltage between the high mounted stoplamp C475-1, circuit CLS17 (YE/GY), harness side and the high mounted stoplamp C475-2, circuit GD150 (BK/WH), harness side. - Is the voltage greater than 10 volts? Yes INSTALL a new high mounted stoplamp. TEST the system for normal operation. No Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8510 REPAIR circuit GD150 (BK/WH) for an open. TEST the system for normal operation. ------------------------------------------------- J4 CHECK FOR VOLTAGE TO THE SJB - Disconnect: SJB C2280b. - While applying the brake pedal, measure the voltage between the SJB C2280b-40, circuit CLS17 (YE/GY), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to J13. No REPAIR circuit CLS17 (YE/GY) for an open. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J5 USE THE RECORDED DTCs FROM THE SJB SELF-TEST - Check the recorded results from the SJB on-demand self-test. - Is DTC B2044 or B2046 present? Yes GO to J6. No GO to J10. ------------------------------------------------- J6 CHECK THE TRAILER TOW TURN RELAY - Disconnect: LH Trailer Tow Turn Relay (DTC B2044). - Disconnect: RH Trailer Tow Turn Relay (DTC B2046). - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Repeat the SJB on-demand self-test. - Is on-demand DTC B2044 or B2046 retrieved again? Yes GO to J7. No INSTALL a new trailer tow stop/turn relay. TEST the system for normal operation. ------------------------------------------------- J7 CHECK THE BULB HOLDER FOR A SHORT TO GROUND - Disconnect: LH Rear Lamp C4035 (DTC B2044, Expedition). - Disconnect: LH Rear Lamp C4112 (DTC B2044, Navigator). - Disconnect: RH Rear Lamp C4032 (DTC B2046, Expedition). - Disconnect: RH Rear Lamp C4114 (DTC B2046, Navigator). - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Repeat the SJB on-demand self-test. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8511 - Is on-demand DTC B2044 or B2046 retrieved again? Yes For Navigator, GO to J8. For Expedition, GO to J9. No INSTALL a new bulb holder. TEST the system for normal operation. ------------------------------------------------- J8 CHECK THE BULB HOLDER FOR A SHORT TO GROUND (NAVIGATOR SECOND LAMP) - Disconnect: LH Rear Lamp C4113 (DTC B2044). - Disconnect: RH Rear Lamp C4115 (DTC B2046). - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Repeat the SJB on-demand self-test. - Is on-demand DTC B2044 or B2046 retrieved again? Yes GO to J9. No INSTALL a new bulb holder. TEST the system for normal operation. ------------------------------------------------- J9 CHECK THE SJB STOPLAMP OUTPUT CIRCUIT FOR A SHORT TO GROUND - Ignition OFF. - Disconnect: SJB C2280d. - Measure the resistance between the SJB C2280d-25, circuit CLS18 (GY/BN), harness side and ground; or between the SJB C2280d-26, circuit CLS19 (VT/OG), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to J13. No REPAIR circuit CLS18 (GY/BN) (LH rear stoplamp) or circuit CLS19 (VT/OG) (RH rear stoplamp) for a short to ground. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. ------------------------------------------------- J10 CHECK FOR VOLTAGE TO THE INOPERATIVE STOPLAMP - Disconnect: Inoperative Rear Lamp. - While applying the brake pedal, measure the voltage between the inoperative rear lamp, harness side and ground as follows: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8512 - Is the voltage greater than 10 volts? Yes GO to J12. No For Expedition, GO to J11. For Navigator if both lamps on one side are inoperative, GO to J11. For Navigator if one lamp is inoperative, REPAIR circuit CLS18 (GY/BN) (LH rear stoplamp) or circuit CLS19 (VT/OG) (RH rear stoplamp) for an open. TEST the system for normal operation. ------------------------------------------------- J11 CHECK THE SJB STOPLAMP OUTPUT CIRCUIT FOR AN OPEN - Disconnect: SJB C2280d. - Measure the resistance between the inoperative rear lamp, harness side and the SJB, harness side; and between the inoperative rear lamp, harness side and ground as follows: - Is the resistance less than 5 ohms? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8513 Yes GO to J13. No REPAIR circuit CLS18 (GY/BN) (LH rear stoplamp) or circuit CLS19 (VT/OG) (RH rear stoplamp) for an open. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J12 CHECK FOR VOLTAGE TO THE INOPERATIVE STOPLAMP USING THE CONNECTOR GROUND - While applying the brake pedal, measure the voltage between the inoperative rear lamp, harness side and ground as follows: - Is the voltages greater than 10 volts? Yes INSTALL a new bulb holder. CLEAR the DTCs. REPEAT the self-test. No REPAIR circuit GD149 (BK/GY) (LH rear stoplamp) or circuit GD150 (BK/WH) (RH rear stoplamp) for an open. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J13 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8514 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 K: The Stoplamps Are On Continuously Stoplamps Pinpoint Tests Pinpoint Test K: 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 When the brake pedal is applied, the stoplamp switch routes voltage to the Smart Junction Box (SJB) and the high mounted stoplamp, the PCM, the ABS module and the Trailer Brake Control (TBC) module through circuit CLS17 (YE/GY). When the SJB detects the brake pedal applied, the SJB provides voltage to the LH rear stoplamp(s) and trailer tow turn relay through circuit CLS18 (GY/BN) and to the RH rear stoplamp(s) and trailer tow turn relay through circuit CLS19 (VT/OG). - DTC B1485 (Brake Pedal Input Short to Battery) - an on-demand DTC that sets when the SJB detects a short to voltage from the stoplamp switch input circuit. - DTC B2045 (Left Rear Stop Lamp Circuit Open) - an on-demand DTC that sets when the SJB detects a short to voltage on the LH rear stop/turn lamp voltage supply circuit. - DTC B2047 (Right Rear Stop Lamp Circuit Open) - an on-demand DTC that sets when the SJB detects a short to voltage on the RH rear stop/turn lamp voltage supply circuit. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Stoplamp switch - TBC module - ABS module - PCM - SJB PINPOINT TEST K: THE STOPLAMPS ARE ON CONTINUOUSLY ------------------------------------------------- K1 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 K3. No GO to K2. ------------------------------------------------- K2 CHECK THE SJB STOPLAMP OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE - Disconnect: SJB C2280d. - Do the stoplamps continue to illuminate? Yes If the LH rear lamp continues to illuminate, REPAIR circuit CLS18 (GY/BN) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8515 If the RH rear lamp continues to illuminate, REPAIR circuit CLS19 (VT/OG) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. No GO to K10. ------------------------------------------------- K3 CHECK THE STOPLAMP SWITCH - Disconnect: Stoplamp Switch C278. - Do the stoplamps continue to illuminate? Yes If the vehicle is equipped with a TBC module, GO to K4. If the vehicle is not equipped with a TBC module, GO to K5. No INSTALL a new stoplamp switch. REFER to Stoplamp Switch See: Brake Light Switch/Service and Repair. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- K4 CHECK THE TBC MODULE - Disconnect: TBC Module C2142. - Do the stoplamps continue to illuminate? Yes GO to K5. No INSTALL a new TBC module. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- K5 CHECK THE PCM - Disconnect: PCM C175b. - Do the stoplamps continue to illuminate? Yes GO to K6. No GO to K8. ------------------------------------------------- K6 CHECK THE ABS MODULE - Disconnect: ABS Module C135. Do the stoplamps continue to illuminate? Yes GO to K7. No GO to K9. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8516 K7 CHECK THE STOPLAMP SWITCH OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE - Disconnect: SJB C2280d. - Does the high mounted stoplamp continue to illuminate? Yes REPAIR circuit CLS17 (YE/GY) for a short to voltage. CLEAR the DTCs. REPEAT the self-test. No GO to K10. ------------------------------------------------- K8 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 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. ------------------------------------------------- K9 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. ------------------------------------------------- K10 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8517 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. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment Technical Service Bulletin # 09C09 Date: 090817 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on June 17, 2009. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8526 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8527 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8528 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8529 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > NHTSA09V232000 > Jun > 09 > Recall 09V232000: Brake Light Switch Adjustment Brake Light Switch: Recalls Recall 09V232000: Brake Light Switch Adjustment VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Expedition 2009 Lincoln/Navigator 2009 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: June 23, 2009 NHTSA CAMPAIGN ID NUMBER: 09V232000 NHTSA ACTION NUMBER: N/A COMPONENT: Service Brakes, Hydraulic: Switches: Brake Light POTENTIAL NUMBER OF UNITS AFFECTED: 1357 SUMMARY: Ford is recalling 1,357 M/Y 2009 Expedition and Navigator vehicles for failing to comply with the Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment." The brake stop lamp switch may be improperly adjusted. This may result in a delay in brake stoplamp illumination when the brake pedal is depressed. In situations of very mild brake application, the brake stoplamps may not illuminate. CONSEQUENCE: Delay or loss of brake stoplamp function may increase the risk of a crash. REMEDY: Dealers will adjust the brake stoplamp switch free of charge. The recall is expected to begin on or before July 6, 2009. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332 or www.ownerconnection.com. NOTES: Ford recall No. 09C09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance Technical Service Bulletin # 09C09 Date: 090617 Attachment I - Administrative Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8538 OASIS ACTIVATED? Yes, OASIS will be activated on June 17,2009. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8539 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8540 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8541 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment Technical Service Bulletin # 09C09 Date: 090817 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on June 17, 2009. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8547 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8548 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8549 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8550 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > NHTSA09V232000 > Jun > 09 > Recall 09V232000: Brake Light Switch Adjustment Brake Light Switch: All Technical Service Bulletins Recall 09V232000: Brake Light Switch Adjustment VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Expedition 2009 Lincoln/Navigator 2009 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: June 23, 2009 NHTSA CAMPAIGN ID NUMBER: 09V232000 NHTSA ACTION NUMBER: N/A COMPONENT: Service Brakes, Hydraulic: Switches: Brake Light POTENTIAL NUMBER OF UNITS AFFECTED: 1357 SUMMARY: Ford is recalling 1,357 M/Y 2009 Expedition and Navigator vehicles for failing to comply with the Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment." The brake stop lamp switch may be improperly adjusted. This may result in a delay in brake stoplamp illumination when the brake pedal is depressed. In situations of very mild brake application, the brake stoplamps may not illuminate. CONSEQUENCE: Delay or loss of brake stoplamp function may increase the risk of a crash. REMEDY: Dealers will adjust the brake stoplamp switch free of charge. The recall is expected to begin on or before July 6, 2009. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332 or www.ownerconnection.com. NOTES: Ford recall No. 09C09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance Technical Service Bulletin # 09C09 Date: 090617 Attachment I - Administrative Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8559 OASIS ACTIVATED? Yes, OASIS will be activated on June 17,2009. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8560 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8561 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8562 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8563 Brake Light Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8564 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8565 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8566 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8567 Brake Light Switch: Service and Repair Stoplamp Switch Removal 1. Disconnect the stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 N [1-3 lb]), pull rearward on the brake pedal, rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. Installation NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the stoplamp switch. Failure to follow these instructions may damage the stoplamp switch. 1. Without movement to the brake pedal assembly, install the stoplamp switch and rotate 45 degrees counterclockwise. 2. Connect the stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Page 8571 Cargo Lamp: Service and Repair Cargo Lamp Removal and Installation 1. Remove the cargo lamp lens. 2. Release the 2 retaining clips (through the access holes) and remove the cargo lamp. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (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). NOTE: When installing a new SJB, it must be configured for this feature, if originally equipped. Refer to Information Bus. The SJB controls the Daytime Running Lamps (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 When the DRL is active, the SJB provides a pulse-width modulated voltage to the low beam headlamps. This illuminates the headlamps at a reduced intensity. The SJB can be configured to turn the DRL on for this vehicle. Refer to Information Bus for additional information on this programmable parameter. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8586 - 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: - 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 the DTCs retrieved are related to the concern, refer to the 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 8. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8587 Daytime Running Lamp: Symptom Related Diagnostic Procedures Daytime Running Lamps (DRL) Symptom Chart Symptom Chart Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8588 Daytime Running Lamp: Pinpoint Tests Daytime Running Lamps (DRL) Pinpoint Tests Pinpoint Test AF: 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 not in PARK (P), the Smart Junction Box (SJB) illuminates the headlamps at a reduced intensity. This pinpoint test is intended to diagnose the following: - Exterior lighting system input/output - SJB configuration - Ignition switch input - Transmission gear input - SJB PINPOINT TEST AF: THE DRL ARE INOPERATIVE ------------------------------------------------- AF1 VERIFY THE DRL OPERATION - Ignition ON. - Make sure the headlamp switch is in the OFF position. - Place the gear selector lever in any gear other than PARK (P). - Do the DRL illuminate? Yes The system is operating correctly. INFORM the customer of the conditions required for the DRL to operate correctly. No GO to AF2. ------------------------------------------------- AF2 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 AF3. No REFER to Headlamps See: Headlamp/Testing and Inspection. ------------------------------------------------- AF3 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 PID (IGN_O_ECU, IGN_A_ECU, IGN_R_ECU, and IGN_S_ECU) while cycling the ignition switch through all its positions. - Do the PIDs agree with the ignition switch positions? Yes GO to AF4. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8589 No REFER to Steering Column to diagnose the input from the ignition switch. See: Steering and Suspension/Steering/Steering Column/Testing and Inspection ------------------------------------------------- AF4 CHECK THE TRANSMISSION GEAR INPUT - Enter the following diagnostic mode on the scan tool: TCM DataLogger. - Monitor the 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 GO to AF5. No REFER to Transmission Control Systems to diagnose the transmission range input. See: Powertrain Management/Transmission Control Systems/Testing and Inspection ------------------------------------------------- AF5 CHECK THE SJB FOR DRL CONFIGURATION - Enter the following diagnostic mode on the scan tool: SJB Configuration. - Check the SJB configuration and make sure the DRL feature is enabled. - Is the SJB DRL configuration enabled? Yes INSTALL a new SJB. TEST the system for normal operation. No ENABLE the DRL configuration. TEST the system for normal operation. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Page 8590 Daytime Running Lamp: Adjustments Autolamps Time Delay Adjustment NOTE: The time delay can be programmed through the instrument cluster message center using the message center buttons (if equipped) or using the following steps. NOTE: Steps 2 through 5 must be carried out within a 10-second period. 1. Start with the ignition switch off 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Instrument Panel Dimmer Switch NOTE: Navigator shown, Expedition similar. Removal and Installation 1. Remove the Instrument Cluster (IC) finish panel. 2. Press the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp Dome Lamp: Service and Repair Interior Lamp Interior Lamp Front Interior Lamp (Except Expedition XLS) NOTE: Overhead console with roof opening panel shown. Other consoles are similar. Front Interior Lamp (Expedition XLS) Removal and Installation Front interior lamp (except Expedition XLS) 1. NOTE: Do not pull down on the front of the overhead console. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp > Page 8598 Pull down on the rear of the overhead console to remove the overhead console from the retaining clips. - Disconnect the electrical connectors. 2. Release the 4 retaining clips, and remove the lamp assembly from the overhead console. 3. Release the 6 retaining clips, and remove the lens from the lamp assembly. NOTE: The bulbs can be pushed out from the backside of the lamp assembly. Replace the bulb(s) as necessary. Front interior lamp (Expedition XLS) 4. Remove the interior lamp lens. 5. Release the 2 retaining clips (through the access holes) and remove the interior lamp. - Disconnect the electrical connector. All interior lamps 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp > Page 8599 Dome Lamp: Service and Repair Interior/Map Reading Lamp Interior/Map Reading Lamp Removal and Installation 1. Release the tab on the front side of the lens. 2. Tilt the front of the lens down. 3. Remove the lamp. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8604 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8605 Door Switch: Locations Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8606 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8607 Door Switch: Locations Door Ajar Switch, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8608 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8611 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8612 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8613 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 8614 Door Switch: Service and Repair Door Ajar Switch NOTE: LH front door latch shown, others similar. Removal and Installation 1. Remove the 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 or Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Service and Repair Exterior Lighting Module: Service and Repair Ballast Removal and Installation NOTE: Make sure that the headlamp switch and the ignition switch are in the OFF position. 1. Remove the headlamp assembly. For additional information, refer to Headlamp Assembly See: Headlamp/Service and Repair. 2. Remove the 4 bolts and the ballast. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 NOTE: Expedition shown, Navigator similar. 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 until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the fog lamp with the bulb removed from the fog lamp. NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the electrical connector and remove the fog lamp bulb. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 8626 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 8627 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 8628 Hazard Warning Switch: Service and Repair Hazard Flasher Lamp Switch NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Remove the instrument panel center finish panel. 2. Release the tabs and remove the hazard flasher lamp switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair Headlamp Bulb Expedition Headlamp Navigator High Intensity Discharge (HID) Headlamp 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 headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamp with the bulb removed from the headlamp. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 8633 NOTE: Make sure that the headlamp switch and the ignition switch are in the OFF position. All vehicles 1. Remove the headlamp assembly. For additional information, refer to Headlamp Assembly See: Service and Repair. Expedition 2. Rotate the headlamp bulb approximately 1/8 turn counterclockwise and remove the bulb from the headlamp assembly. Navigator 3. Remove the High Intensity Discharge (HID) bulb access cover. 4. Remove the 2 screws and the HID bulb. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 8637 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 8640 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8643 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8644 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8645 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 8646 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left > Page 8651 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 8654 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 8655 Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 8656 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8660 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8661 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8662 Headlamp Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8663 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8664 Headlamp Switch: Service and Repair Headlamp Switch Expedition Navigator Removal and Installation Expedition Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8665 1. Remove the screw and the LH lower instrument panel finish panel. - Disconnect the electrical connector. Navigator 2. Remove the 3 screws and the steering column finish panel. - Disconnect the electrical connectors. All vehicles 3. NOTE: The headlamp switch is removed by releasing the tabs and pushing from behind. Remove the headlamp switch. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Horn Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 8673 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 8674 Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8679 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8680 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8681 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8682 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8683 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8684 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8685 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8686 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 License Plate Lamp: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8698 92-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8699 92-3 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 Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8704 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8705 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8706 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8707 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8708 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8709 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8710 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8711 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8712 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8713 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8714 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8715 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8716 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8717 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8718 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8719 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8720 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8721 Marker Lamp: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8722 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8723 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8724 92-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8725 92-3 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking 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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8730 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8731 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8732 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8733 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8734 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8735 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8736 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8737 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8738 Parking 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8739 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8740 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8741 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8742 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8743 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8744 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8745 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8746 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8747 Parking Lamp: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8748 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8749 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8750 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8751 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8752 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8753 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8754 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8755 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8756 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8757 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8758 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8759 Parking 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8760 92-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8761 92-3 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Parking Lamp: Initial Inspection and Diagnostic Overview Principles Of Operation Parking, Rear and License Plate Lamps Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The SJB monitors the headlamp switch position by sending voltage reference signals on multiple circuits to the headlamp switch. At any given time, one of the signal circuits is routed to ground. If the SJB does not detect any of the inputs to the headlamp switch as active (routed to ground) for 5 seconds, the SJB turns on the exterior lights and keeps them on for 10 minutes after the ignition switch is turned off (or 10 minutes from the time the SJB does not detect any headlamp switch input if the ignition switch was already off). If the SJB detects multiple circuits short to ground, the SJB implements a planned strategy depending on the multiple inputs received. Based on the multiple inputs received, the autolamps, the headlamps and/or the parking lamps are turned on. If either of these situations occur, the SJB should not be ruled immediately as being at fault. This is normal behavior of the SJB when it has detected a fault with the inputs from the headlamp switch. When the SJB receives an input from the headlamp switch indicating a request for the parking lamps, the SJB energizes the parking lamp relay, which supplies voltage to the exterior lamps. Special Tools Used With Diagnostics Parking, Rear and License Plate Lamps Inspection And Verification Parking, Rear and License Plate Lamps Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8764 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 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 the 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8765 Parking Lamp: Symptom Related Diagnostic Procedures Parking, Rear and License Plate Lamps Symptom Chart Symptom Chart Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8766 Parking Lamp: Pinpoint Tests Pinpoint Test P: One Or More Parking, Rear Or License Plate Lamps Is Inoperative Parking, Rear and License Plate Lamps Pinpoint Tests Pinpoint Test P: One Or More Parking, Rear or License Plate Lamps Is Inoperative Refer to Wiring Diagram Set 92, Parking, Rear and License Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation When the headlamp switch is placed in the PARKING LAMPS ON position, the Smart Junction Box (SJB) provides a ground for the parking lamp relay coil (integrated into the SJB). When the parking lamp relay is energized, voltage is routed through circuit CLS30 (VT/WH) to the rear and front parking lamps. Ground is provided to the rear parking, liftgate and license plate lamps through circuits GD149 (BK/GY) and GD150 (BK/WH). Ground is provided to the front parking and side marker lamps through circuits GD120 (BK/GN) and GD123 (BK/GY). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Bulb holder - SJB PINPOINT TEST P: ONE OR MORE PARKING, REAR OR LICENSE PLATE LAMPS IS INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- P1 DETERMINE IF ALL THE PARKING LAMPS ARE INOPERATIVE - Ignition OFF. - Place the headlamp switch in the PARKING LAMPS ON position. - Are all the parking lamps inoperative? Yes PLACE the headlamp switch in the OFF position. VERIFY the SJB fuse 22 (15A) is OK. If OK, GO to P6. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. No If all the front parking lamps are inoperative, GO to P2. If all the rear parking and license plate lamps are inoperative, GO to P3. For all other inoperative lamps, GO to P4. ------------------------------------------------- P2 CHECK THE SJB FRONT PARKING LAMPS OUTPUT CIRCUIT FOR AN OPEN - Disconnect: SJB C2280e. - Connect a fused jumper wire between the SJB C2280e-1, circuit CBB56 (BU/GN), harness side and the SJB C2280e-6, circuit CLS30 (VT/WH), harness side. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8767 - Ignition ON. - Do the front parking lamps illuminate? Yes REMOVE the jumper wire. GO to P6. No REMOVE the jumper wire. REPAIR circuit CLS30 (VT/WH) for an open. TEST the system for normal operation. ------------------------------------------------- P3 CHECK THE SJB REAR PARKING LAMPS OUTPUT CIRCUIT FOR AN OPEN - Disconnect: SJB C2280d. - Connect a fused jumper wire between the positive battery terminal and the SJB C2280d-20, circuit CLS30 (VT/WH), harness side. - Do the rear parking lamps illuminate? Yes REMOVE the jumper wire. GO to P6. No REMOVE the jumper wire. REPAIR circuit CLS30 (VT/WH) for an open. TEST the system for normal operation. ------------------------------------------------- P4 CHECK FOR VOLTAGE TO THE INOPERATIVE PARKING LAMP(S) - Place the headlamp switch in the OFF position. - Disconnect: Inoperative Lamp. - Place the headlamp switch in the PARKING LAMPS ON position. - Measure the voltage between the inoperative lamp, harness side and ground as follows: Expedition Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8768 Navigator - Is the voltage greater than 10 volts? Yes For the license plate lamp(s), REPAIR circuit 57 (BK) or circuit GD150 (BK/WH) for an open. TEST the system for normal operation. For all other lamps, GO to P5. No REPAIR circuit CLS30 (VT/WH) for an open. TEST the system for normal operation. ------------------------------------------------- P5 CHECK THE PARKING LAMP GROUND CIRCUIT FOR AN OPEN - Measure the voltage between the inoperative lamp, harness side and ground as follows: Expedition Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8769 Navigator - Is the voltage greater than 10 volts? Yes INSTALL a new bulb holder. TEST the system for normal operation. No REPAIR the ground circuit in question for an open. TEST the system for normal operation. ------------------------------------------------- P6 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 Q: The Parking, Rear Or License Plate Lamps Are On Continuously Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8770 Parking, Rear and License Plate Lamps Pinpoint Tests Pinpoint Test Q: The Parking, Rear Or License Plate Lamps Are On Continuously Refer to Wiring Diagram Set 92, Parking, Rear and License Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (SJB) monitors the parking lamp request input from the headlamp switch through circuit CLS05 (BU/GY). The SJB provides a ground for the parking lamp relay coil (integrated into the SJB) when a request for the parking lamps is received. When the parking lamp relay is energized, voltage is routed through circuit CLS30 (VT/WH) to the rear and front parking lamps. - DTC B1578 (Lamp Park Input Circuit Short to Ground) - an on-demand DTC that may set when the SJB detects a short to ground in the parking lamps on input circuit. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Headlamp switch - SJB PINPOINT TEST Q: THE PARKING, REAR OR LICENSE PLATE LAMPS ARE ON CONTINUOUSLY ------------------------------------------------- Q1 USE THE RECORDED DTCs FROM THE SJB SELF-TEST - Check the recorded results from the SJB self-test. - Was DTC B1578 recorded? Yes GO to Q2. No GO to Q4. ------------------------------------------------- Q2 CHECK THE HEADLAMP SWITCH - Ignition OFF. - Disconnect: Headlamp Switch C205. - Carry out the headlamp switch component test. - Is the headlamp switch OK? Yes GO to Q3. No INSTALL a new headlamp switch. REFER to Headlamp Switch See: Headlamp/Headlamp Switch/Service and Repair. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- Q3 CHECK CIRCUIT CLS05 (BU/GY) FOR A SHORT TO GROUND - Disconnect: SJB C2280b. - Measure the resistance between the headlamp switch C205-5, circuit CLS05 (BU/GY), harness side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8771 - Is the resistance greater than 10,000 ohms? Yes GO to Q7. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- Q4 CHECK THE SJB REAR PARKING LAMPS OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE - Ignition OFF. - Disconnect: SJB C2280d. - Ignition ON. - Do the rear parking lamps continue to illuminate? Yes If not equipped with remote start, REPAIR circuit CLS30 (VT/WH) for a short to voltage. TEST the system for normal operation. If equipped with remote start, GO to Q5. No GO to Q6. ------------------------------------------------- Q5 ISOLATE THE REMOTE START SYSTEM - Disconnect: Remote Start C2390. - Do the rear lamps continue to illuminate? Yes REPAIR circuit CLS30 (VT/WH) for a short to voltage. TEST the system for normal operation. No INSTALL a new remote start. TEST the system for normal operation. ------------------------------------------------- Q6 CHECK THE SJB FRONT PARKING LAMPS OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE - Ignition OFF. - Disconnect: SJB C2280e. - Ignition ON. - Do the front parking lamps continue to illuminate? Yes REPAIR circuit CLS30 (VT/WH) for a short to voltage. TEST the system for normal operation. No GO to Q6. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8772 ------------------------------------------------- Q7 CHECK FOR CORRECT SJB OPERATION - Ignition OFF. - 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. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Page 8773 Parking Lamp: Service and Repair Parking Lamp - Liftgate Removal and Installation 1. Remove the liftgate trim panel. - Remove the water shield. 2. Remove the 4 nuts and the liftgate parking lamp. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Service and Repair Exterior Lighting Module: Service and Repair Ballast Removal and Installation NOTE: Make sure that the headlamp switch and the ignition switch are in the OFF position. 1. Remove the headlamp assembly. For additional information, refer to Headlamp Assembly See: Headlamp/Service and Repair. 2. Remove the 4 bolts and the ballast. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > High Intensity Discharge Headlamp Relay, Left > Page 8785 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 8788 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 8789 Headlamp Relay: Testing and Inspection High Intensity Discharge Headlamp Relay, Right Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > High Intensity Discharge Headlamp Relay, Left > Page 8790 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 8798 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 8799 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 8800 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 8803 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 8804 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 8805 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair Light Sensor NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Using a suitable tool (such as a pocket screwdriver), remove the light sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment Technical Service Bulletin # 09C09 Date: 090817 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on June 17, 2009. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment > Page 8818 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment > Page 8819 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment > Page 8820 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Aug > 09 > Recall Brake Light Switch Adjustment > Page 8821 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > NHTSA09V232000 > Jun > 09 > Recall 09V232000: Brake Light Switch Adjustment Brake Light Switch: Recalls Recall 09V232000: Brake Light Switch Adjustment VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Expedition 2009 Lincoln/Navigator 2009 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: June 23, 2009 NHTSA CAMPAIGN ID NUMBER: 09V232000 NHTSA ACTION NUMBER: N/A COMPONENT: Service Brakes, Hydraulic: Switches: Brake Light POTENTIAL NUMBER OF UNITS AFFECTED: 1357 SUMMARY: Ford is recalling 1,357 M/Y 2009 Expedition and Navigator vehicles for failing to comply with the Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment." The brake stop lamp switch may be improperly adjusted. This may result in a delay in brake stoplamp illumination when the brake pedal is depressed. In situations of very mild brake application, the brake stoplamps may not illuminate. CONSEQUENCE: Delay or loss of brake stoplamp function may increase the risk of a crash. REMEDY: Dealers will adjust the brake stoplamp switch free of charge. The recall is expected to begin on or before July 6, 2009. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332 or www.ownerconnection.com. NOTES: Ford recall No. 09C09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance Technical Service Bulletin # 09C09 Date: 090617 Attachment I - Administrative Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8830 OASIS ACTIVATED? Yes, OASIS will be activated on June 17,2009. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8831 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8832 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Recalls for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8833 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment Technical Service Bulletin # 09C09 Date: 090817 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on June 17, 2009. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8839 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8840 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8841 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Aug > 09 > Recall - Brake Light Switch Adjustment > Page 8842 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > NHTSA09V232000 > Jun > 09 > Recall 09V232000: Brake Light Switch Adjustment Brake Light Switch: All Technical Service Bulletins Recall 09V232000: Brake Light Switch Adjustment VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Expedition 2009 Lincoln/Navigator 2009 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: June 23, 2009 NHTSA CAMPAIGN ID NUMBER: 09V232000 NHTSA ACTION NUMBER: N/A COMPONENT: Service Brakes, Hydraulic: Switches: Brake Light POTENTIAL NUMBER OF UNITS AFFECTED: 1357 SUMMARY: Ford is recalling 1,357 M/Y 2009 Expedition and Navigator vehicles for failing to comply with the Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment." The brake stop lamp switch may be improperly adjusted. This may result in a delay in brake stoplamp illumination when the brake pedal is depressed. In situations of very mild brake application, the brake stoplamps may not illuminate. CONSEQUENCE: Delay or loss of brake stoplamp function may increase the risk of a crash. REMEDY: Dealers will adjust the brake stoplamp switch free of charge. The recall is expected to begin on or before July 6, 2009. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332 or www.ownerconnection.com. NOTES: Ford recall No. 09C09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance Technical Service Bulletin # 09C09 Date: 090617 Attachment I - Administrative Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8851 OASIS ACTIVATED? Yes, OASIS will be activated on June 17,2009. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by June 17, 2009. Owner names and addresses will be available by July 13, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. Attachment II - Labor and Parts Information Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8852 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this repair. Attachment III - Technical Information OVERVIEW This program involves adjustment of the brake stoplamp switch by removing and reinstalling it. SERVICE PROCEDURE NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the brake stoplamp switch. Failure to follow these instructions may damage the brake stoplamp switch. 1. Disconnect the brake stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 Pounds [4-16 Newtons]), pull rearward on the brake pedal, rotate the brake stoplamp switch 45 degrees clockwise and remove the brake stoplamp switch. 3. Without movement to the brake pedal assembly, install the brake stoplamp switch and rotate 45 degrees counterclockwise. 4. Connect the brake stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8853 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Light Switch: > 09C09 > Jun > 09 > Recall - Brake Light Switch Non-Compliance > Page 8854 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8855 Brake Light Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8856 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8857 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8858 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Technical Service Bulletins > Page 8859 Brake Light Switch: Service and Repair Stoplamp Switch Removal 1. Disconnect the stoplamp switch electrical connector. 2. NOTE: The stoplamp switch will be difficult to remove if the switch plunger is not depressed. A slight rearward force should be adequate to depress the plunger. With a light force (approximately 1-4 N [1-3 lb]), pull rearward on the brake pedal, rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. Installation NOTICE: It is very important to not press, pull or touch the brake pedal assembly during the installation of the stoplamp switch. Failure to follow these instructions may damage the stoplamp switch. 1. Without movement to the brake pedal assembly, install the stoplamp switch and rotate 45 degrees counterclockwise. 2. Connect the stoplamp switch electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8864 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8865 Door Switch: Locations Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8866 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8867 Door Switch: Locations Door Ajar Switch, Right Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 8868 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8871 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8872 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8873 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 8874 Door Switch: Service and Repair Door Ajar Switch NOTE: LH front door latch shown, others similar. Removal and Installation 1. Remove the 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 or Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 8878 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 8879 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 8880 Hazard Warning Switch: Service and Repair Hazard Flasher Lamp Switch NOTE: Expedition shown, Navigator similar. Removal and Installation 1. Remove the instrument panel center finish panel. 2. Release the tabs and remove the hazard flasher lamp switch. 3. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 8884 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 8887 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 8890 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8891 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (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 8892 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 8893 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8897 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8898 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8899 Headlamp Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8900 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8901 Headlamp Switch: Service and Repair Headlamp Switch Expedition Navigator Removal and Installation Expedition Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8902 1. Remove the screw and the LH lower instrument panel finish panel. - Disconnect the electrical connector. Navigator 2. Remove the 3 screws and the steering column finish panel. - Disconnect the electrical connectors. All vehicles 3. NOTE: The headlamp switch is removed by releasing the tabs and pushing from behind. Remove the headlamp switch. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 8906 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 8907 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8911 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8912 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8913 Turn Signal Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8914 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8915 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8920 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8921 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8922 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8923 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8924 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8925 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8926 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8927 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8928 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8929 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8930 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8931 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8932 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8933 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8934 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8935 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8936 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8937 Tail Lamp: Connector Views Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8938 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8939 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8940 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8941 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8942 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8943 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8944 92-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8945 92-3 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 Expedition 2wd Workshop Manual (V8-5.4L (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. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8950 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 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8951 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 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8952 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. 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 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8953 Symbols (Part 1) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8954 Symbols (Part 2) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8955 Symbols (Part 3) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8956 Symbols (Part 4) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8957 Symbols (Part 5) Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8958 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 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8959 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 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8960 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8961 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8962 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8963 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. 6. Center one end of the wire splice in the appropriate crimping chamber. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8964 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8965 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8966 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8967 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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8968 95-2 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8969 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 Expedition 2wd Workshop Manual (V8-5.4L (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 trailer lamps and battery charge are supplied power by relays that are energized to correspond with the exterior lighting functions of the vehicle. If equipped, the vehicle also supplies circuitry to support the installation of an aftermarket Trailer Brake Control (TBC) module (installed by the customer). The vehicle circuitry only supplies voltage, ground, stoplamp switch input and a controlling circuit to the trailer tow connector. The trailer electric brakes themselves are controlled by the aftermarket TBC module and not the vehicle itself. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8972 Visual Inspection Chart 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8973 Trailer Lamps: Symptom Related Diagnostic Procedures Trailer Lamps Symptom Chart Symptom Chart Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8974 Trailer Lamps: Pinpoint Tests Pinpoint Test Y: All The Trailer Lamps Are Inoperative Trailer Lamps Pinpoint Tests Pinpoint Test Y: 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 The trailer tow connectors receive ground through circuit RAT08 (WH) for all of the trailer lamps. The trailer tow parking and stop/turn relays share the same ground through circuit GD123 (BK/GY). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer PINPOINT TEST Y: 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. ------------------------------------------------- Y1 CHECK THE RELAY GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Trailer Tow Parking Lamp Relay. - Measure the voltage between the trailer tow parking lamp relay pin 3, circuit SBB28 (BU/RD), BJB face side and the trailer tow parking lamp relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage greater than 10 volts? Yes GO to Y2. No REPAIR circuit GD123 (BK/GY) for an open. TEST the system for normal operation ------------------------------------------------- Y2 CHECK THE TRAILER TOW CONNECTOR GROUND CIRCUIT FOR AN OPEN THROUGH THE CONNECTOR - Disconnect: Negative Battery Cable. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8975 - For the 4-pin connector, measure the resistance between the trailer tow C4098-4, 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 For the 4-pin connector, REPAIR circuit RAT08 (WH) for an open. TEST the system for normal operation. For the 7-pin connector.GO to Y3. ------------------------------------------------- Y3 CHECK THE TRAILER TOW GROUND CIRCUIT FOR AN OPEN - Disconnect: Trailer Tow C4099. - Measure the resistance between the trailer tow C4099-2, 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 Z: The Individual Trailer Lamp Is Inoperative - Trailer Turn/Stoplamp Trailer Lamps Pinpoint Tests Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - Trailer Turn/Stoplamp Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8976 The Battery Junction Box (BJB) fuse 45 (25A) supplies voltage to both trailer tow turn relays through circuit SBB45 (GY/RD). The trailer tow turn/stop relay coils are provided ground through circuit GD123 (BK/GY). The trailer tow LH turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT09 (GN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow turn relay - Trailer PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - TRAILER TURN/STOPLAMP 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 VERIFY THE TRAILER LAMP OPERATION - Ignition OFF. - Determine if both trailer stop/turn lamps are inoperative. - Are both trailer stop/turn lamps inoperative? Yes VERIFY the BJB fuse 45 (25A) is OK. If OK, REPAIR circuit SBB45 (GY/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. No For an inoperative LH trailer lamp, GO to Z2. For an inoperative RH trailer lamp, GO to Z8. ------------------------------------------------- Z2 CHECK FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR (LH TRAILER STOP/TURN LAMP) - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4098-2, 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8977 - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No For the 4-pin connector, GO to Z4. For the 7-pin connector, GO to Z3. ------------------------------------------------- Z3 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (LH STOP/TURN 7-PIN) - Disconnect: Trailer Tow C4099. - While applying the brake pedal, measure the voltage between the trailer tow C4099-1, 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 Z4. ------------------------------------------------- Z4 CHECK THE TRAILER TOW LH STOP/TURN RELAY - Disconnect: Trailer Tow LH Stop/Turn Relay. - Substitute a known good relay. - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4098-2, circuit CAT06 (YE), harness side and ground. - For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4099-1, circuit CAT06 (YE), harness side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8978 - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer tow turn relay. TEST the system for normal operation. No REMOVE the known good relay. GO to Z5. ------------------------------------------------- Z5 CHECK FOR VOLTAGE TO THE LH STOP/TURN LAMP RELAY COIL - While applying the brake pedal, measure the voltage between the trailer tow LH turn relay pin 1, circuit CLS18 (GY/BN), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z6. No REPAIR circuit CLS18 (GY/BN) for an open. TEST the system for normal operation. ------------------------------------------------- Z6 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE LH STOP/TURN LAMP RELAY - Measure the voltage between the trailer tow LH turn relay pin 3, circuit SBB45 (GY/RD), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z7. No REPAIR circuit SBB45 (GY/RD) for an open. TEST the system for normal operation. ------------------------------------------------- Z7 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE LH STOP/TURN LAMP RELAY USING THE RELAY GROUND PIN - Measure the voltage between the trailer tow LH turn relay pin 3, circuit SBB45 (GY/RD), BJB face side and the trailer tow LH turn relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage greater than 10 volts? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8979 Yes REPAIR circuit CAT06 (YE) for an open. TEST the system for normal operation. No REPAIR circuit GD123 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------- Z8 CHECK FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR (RH TRAILER STOP/TURN LAMP) - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4098-1, 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. No For the 4-pin connector, GO to Z10. For the 7-pin connector, GO to Z9. ------------------------------------------------- Z9 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (RH STOP/TURN 7-PIN) - Disconnect: Trailer Tow C4099. - While applying the brake pedal, measure the voltage between the trailer tow C4099-4, 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 Z10. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8980 ------------------------------------------------- Z10 CHECK THE TRAILER TOW RH STOP/TURN RELAY - Disconnect: Trailer Tow RH Stop/Turn Relay. - Substitute a known good relay. - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4098-1, circuit CAT09 (GN), harness side and ground. - For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C4099-4, circuit CAT09 (GN), harness side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer tow turn relay. TEST the system for normal operation. No REMOVE the known good relay. GO to Z11. ------------------------------------------------- Z11 CHECK FOR VOLTAGE TO THE RH STOP/TURN LAMP RELAY COIL - While applying the brake pedal, measure the voltage between the trailer tow RH turn relay pin 1, circuit CLS19 (VT/OG), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to Z12. No REPAIR circuit CLS19 (VT/OG) for an open. TEST the system for normal operation. ------------------------------------------------- Z12 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE RH STOP/TURN LAMP RELAY - Measure the voltage between the trailer tow RH turn relay pin 3, circuit SBB45 (GY/RD), BJB face side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8981 - Is the voltage greater than 10 volts? Yes GO to Z13. No REPAIR circuit SBB45 (GY/RD) for an open. TEST the system for normal operation. ------------------------------------------------- Z13 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE RH STOP/TURN LAMP RELAY USING THE RELAY GROUND PIN - Measure the voltage between the trailer tow RH turn relay pin 3, circuit SBB45 (GY/RD), BJB face side and the trailer tow RH turn relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage less than 5 ohms? Yes REPAIR circuit CAT09 (GN) for an open. TEST the system for normal operation. No REPAIR ground GD123 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps Trailer Lamps Pinpoint Tests Pinpoint Test AA: The Trailer Lamps Are Inoperative - Trailer 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 The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. The trailer tow parking lamp relay coil is provided ground through circuit GD123 (BK/GY). Voltage is supplied from Battery Junction Box (BJB) fuse 28 (25A) to the trailer tow parking lamp relay switch side through circuit SBB28 (GN/RD). When the trailer tow parking lamp relay is energized, voltage is routed to the trailer tow connector through circuit CAT11 (BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow parking lamp relay - Trailer PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8982 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 FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR - Ignition OFF. - Place the headlamp switch in the PARKING LAMPS ON position. - For the 4-pin connector, measure the voltage between the trailer tow C4098-3, circuit CAT11 (BN), harness side and ground. - For the 7-pin connector, measure the voltage between the trailer tow connector pin 6, circuit CAT11 (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 For the 4-pin connector, GO to AA3. For the 7-pin connector, GO to AA2. ------------------------------------------------- AA2 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (7-PIN) - Disconnect: Trailer Tow C4099. - Measure the voltage between the trailer tow C4099-6, circuit CAT11 (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 AA3. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8983 AA3 CHECK THE TRAILER TOW PARKING LAMP RELAY - Place the headlamp switch in the OFF position. - Disconnect: Trailer Tow Parking Lamp Relay. - Substitute a known good relay. - Place the headlamp switch in the PARKING LAMPS ON position. - For the 4-pin connector, measure the voltage between the trailer tow C4098-3, circuit CAT11 (BN), harness side and ground. - For the 7-pin connector, measure the voltage between the trailer tow C4099-6, circuit CAT11 (BN), harness side and ground. - Is the trailer tow parking lamp relay OK? Yes REMOVE the known good relay. GO to AA4. No REMOVE the known good relay. INSTALL a new trailer tow parking lamp relay. TEST the system for normal operation. ------------------------------------------------- AA4 CHECK FOR VOLTAGE TO THE TRAILER TOW PARKING LAMP RELAY COIL - Measure the voltage between the trailer tow parking lamp relay pin 1, circuit CLS30 (VT/WH), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AA5. No REPAIR circuit CLS30 (VT/WH) for an open. TEST the system for normal operation. ------------------------------------------------- AA5 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE TRAILER TOW PARKING LAMP RELAY - Place the headlamp switch in the OFF position. - Measure the voltage between the trailer tow parking lamp relay pin 3, circuit SBB28 (GN/RD), BJB face side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8984 - Is the voltage greater than 10 volts? Yes GO to AA6. No VERIFY the BJB fuse 28 (25A) is OK. If OK, REPAIR circuit SBB28 (GN/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AA6 CHECK THE VOLTAGE SUPPLY CIRCUIT TO THE TRAILER TOW PARKING LAMP RELAY USING THE RELAY GROUND PIN - Measure the voltage between the trailer tow parking lamp relay pin 3, circuit SBB28 (GN/RD), BJB face side and the trailer tow parking lamp relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage greater than 10 volts? Yes REPAIR circuit CAT11 (BN) for an open. TEST the system for normal operation. No REPAIR circuit GD123 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AB: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps Trailer Lamps Pinpoint Tests Pinpoint Test AB: The Trailer Lamps Are Inoperative - Trailer 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 The Battery Junction Box (BJB) fuse 58 (15A) receives voltage from circuit CLS10 (GY/BN) when the vehicle reversing lamps are illuminated. The voltage is then routed to the trailer tow connector through circuit CAT16 (GY/BN). This pinpoint test is intended to diagnose the following: - Fuse Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8985 - Wiring, terminals or connectors - Trailer PINPOINT TEST AB: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING 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. ------------------------------------------------- AB1 CHECK FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR - Ignition OFF. - 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 BJB fuse 58 (15A) is OK. If OK, GO to AB2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AB2 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow C4099. - Measure the voltage between the trailer tow C4099-7, 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 AB3. ------------------------------------------------- AB3 CHECK FOR VOLTAGE TO THE BJB FUSE 58 (15A) - Measure the voltage between the BJB fuse 58 (15A), circuit CLS10 (GY/BN), input side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8986 - Is the voltage greater than 10 volts? Yes REPAIR circuit CAT16 (GY/BN) for an open. TEST the system for normal operation. No REPAIR circuit CLS10 (GY/BN) for an open. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AC: The Trailer Lamps Are On Continuously Trailer Lamps Pinpoint Tests Pinpoint Test AC: 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 - Trailer Tow Turn/Stoplamp The trailer tow LH turn relay coil receives voltage through circuit CLS18 (GY/BN) when the vehicle LH rear stoplamp is illuminated. When the trailer tow LH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT06 (YE). The trailer tow RH turn relay coil receives voltage through circuit CLS19 (VT/OG) when the vehicle RH rear stoplamp is illuminated. When the trailer tow RH turn relay is energized, the voltage is routed to the trailer tow connector through circuit CAT09 (GN). Trailer Tow Parking The trailer tow parking lamp relay coil receives voltage through circuit CLS30 (VT/WH) when the vehicle parking lamps are illuminated. When the trailer tow parking lamp relay is energized, the voltage is routed to the trailer tow connector through circuit CAT11 (BN). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow relay - Trailer PINPOINT TEST AC: 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. ------------------------------------------------- AC1 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR - Ignition ON. - Measure the voltage between the trailer tow 4-pin connector, harness side and ground as follows: Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8987 - Is any voltage present? Yes GO to AC2. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AC2 CHECK THE TRAILER TOW RELAY - Ignition OFF. - Disconnect: Suspect Trailer Tow Relay. - Measure the voltage between the trailer tow 4-pin connector, harness side and ground as follows: - Is any voltage present? Yes REPAIR circuit CAT06 (YE) (LH turn), circuit CAT09 (OG) (RH turn), or circuit CAT11 (BN) (parking lamps) for a short to voltage. TEST the system for normal operation. No INSTALL a new turn trailer tow relay. TEST the system for normal operation. ------------------------------------------------Pinpoint Test AD: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly Trailer Lamps Pinpoint Tests Pinpoint Test AD: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly Normal Operation Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8988 The trailer battery charge relay coil receives voltage from the Smart Junction Box (SJB) fuse 42 (10A) through circuit CAT23 (GY/YE) when the ignition switch is in the RUN position. Ground for the trailer battery charge relay coil is supplied through circuit GD123 (BK/GY). The Battery Junction Box (BJB) fuse 21 (30A) supplies voltage to the trailer battery charge relay switch side through circuit SBB21 (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 - SJB PINPOINT TEST AD: 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. ------------------------------------------------- AD1 CHECK FOR VOLTAGE THROUGH THE TRAILER TOW CONNECTOR (BATTERY CHARGE INOPERATIVE) - 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 AD8. No GO to AD2. ------------------------------------------------- AD2 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR (BATTERY CHARGE INOPERATIVE) - Ignition OFF. - Disconnect: Trailer Tow C4099. - Ignition ON. - Measure the voltage between the trailer tow C4099-5, 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8989 No GO to AD3. ------------------------------------------------- AD3 CHECK THE TRAILER BATTERY CHARGE RELAY (INOPERATIVE) - Ignition OFF. - Disconnect: Trailer Battery Charge Relay. - Substitute a known good relay. - Ignition ON. - Measure the voltage between the trailer tow C4099-5, circuit CAT14 (OG) 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. GO to AD4. ------------------------------------------------- AD4 CHECK FOR VOLTAGE TO THE TRAILER TOW BATTERY CHARGE RELAY - Ignition OFF. - Measure the voltage between the trailer battery charge relay pin 3, circuit SBB21 (GY/RD), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AD5. No VERIFY the BJB fuse 21 (30A) is OK. If OK, REPAIR circuit SBB21 (GY/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AD5 CHECK FOR VOLTAGE TO THE TRAILER TOW BATTERY CHARGE RELAY USING THE RELAY GROUND PIN - Measure the voltage between the trailer battery charge relay pin 3, circuit SBB21 (GY/RD), BJB face side and the trailer battery charge relay pin 2, circuit GD123 (BK/GY), BJB face side. - Is the voltage greater than 10 volts? Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8990 Yes GO to AD6. No REPAIR circuit GD123 (BK/GY) for an open. TEST the system for normal operation. ------------------------------------------------- AD6 CHECK FOR VOLTAGE TO THE TRAILER BATTERY CHARGE RELAY COIL (INOPERATIVE CONDITION) - Ignition ON. - Measure the voltage between the trailer battery charge relay pin 1, circuit CAT23 (GN/YE), BJB face side and ground. - Is the voltage greater than 10 volts? Yes REPAIR circuit CAT14 (OG) for an open. TEST the system for normal operation. No VERIFY the SJB fuse 44 (10A) is OK. If OK, GO to AD7. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AD7 CHECK THE TRAILER BATTERY CHARGE RELAY COIL VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: SJB C2280b. - Measure the resistance between the trailer battery charge relay pin 1, circuit CAT23 (GN/YE), BJB face side and the SJB C2280b-6, circuit CAT23 (GN/YE), harness side. - Is the resistance less than 5 ohms? Yes GO to AD12. No REPAIR circuit CAT23 (GN/YE) for an open. TEST the system for normal operation. ------------------------------------------------- AD8 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8991 - Is any voltage present? Yes GO to AD9. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AD9 CHECK THE TRAILER BATTERY CHARGE VOLTAGE SUPPLY CIRCUIT 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. - Is any voltage present? Yes REPAIR circuit CAT14 (OG) for a short to voltage. TEST the system for normal operation. No GO to AD10. ------------------------------------------------- AD10 CHECK FOR VOLTAGE TO THE TRAILER BATTERY CHARGE RELAY COIL (BATTERY CHARGE ALWAYS ON) - Measure the voltage between the trailer battery charge relay pin 1, circuit CAT23 (GN/YE), BJB face side and ground. - Is any voltage present? Yes GO to AD11. No INSTALL a new trailer battery charge relay. TEST the system for normal operation. ------------------------------------------------- AD11 CHECK THE TRAILER BATTERY CHARGE RELAY COIL SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8992 - Disconnect: SJB C2280b. - Measure the voltage between the trailer battery charge relay pin 1, circuit CAT23 (GN/YE), BJB face side and ground. - Is any voltage present? Yes REPAIR circuit CAT23 (GN/YE) for a short to voltage. TEST the system for normal operation. No GO to AD12. ------------------------------------------------- AD12 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 AE: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly Trailer Lamps Pinpoint Tests Pinpoint Test AE: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly Normal Operation The Trailer Brake Control (TBC) module is provided voltage at all times by the Battery Junction Box (BJB) fuse 18 (30A) through circuit SBB18 (YE/RD). Ground for the TBC module is provided through circuit GD138 (BK/WH). The TBC module receives voltage from the stoplamp switch through circuit CLS17 (YE/GY) when the brake pedal is applied. When requested, the TBC module sends voltage to the trailer tow connector through circuit CAT19 (BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TBC module - Trailer PINPOINT TEST AE: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8993 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. ------------------------------------------------- AE1 CHECK THE TRAILER ELECTRIC BRAKE CONTROLLER FOR A SHORTED OUTPUT - Ignition ON. - With the brake pedal released, measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side and ground. - Is any voltage present? Yes GO to AE2. No GO to AE3. ------------------------------------------------- AE2 CHECK THE TBC MODULE OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE - Disconnect: TBC Module C2142. - Measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side and ground. - Is any voltage present? Yes REPAIR circuit CAT19 (BU) for a short to voltage. TEST the system for normal operation. No INSTALL a new TBC module. TEST the system for normal operation. ------------------------------------------------- AE3 CHECK THE TBC MODULE OUTPUT - Ignition OFF. - Set the gain on the TBC module to the maximum setting. - While applying the brake pedal, measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side and ground. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8994 - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No GO to AE4. ------------------------------------------------- AE4 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow C4099. - NOTE: Make sure the gain is still set to the maximum setting. - While applying the brake pedal, measure the voltage between the trailer tow C4099-3, 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 AE5. ------------------------------------------------- AE5 CHECK FOR VOLTAGE TO THE TBC MODULE - Disconnect: TBC Module C2142. - Measure the voltage between the TBC module C2142-1, circuit SBB18 (YE/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to AE6. No VERIFY the BJB fuse 18 (30A) is OK. If OK, REPAIR circuit SBB18 (YE/RD) for an open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8995 ------------------------------------------------- AE6 CHECK THE STOPLAMP SWITCH INPUT TO THE TBC MODULE - While applying the brake pedal, measure the voltage between the TBC module C2142-2, circuit CLS17 (YE/GY), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to AE7. No REPAIR circuit CLS17 (YE/GY) for an open. TEST the system for normal operation. ------------------------------------------------- AE7 CHECK FOR VOLTAGE TO THE TBC MODULE USING THE CONNECTOR GROUND PIN - While applying the brake pedal, measure the voltage between the TBC module C2142-2, circuit CLS17 (YE/GY), harness side and the TBC module C2142-6, circuit GD138 (BK/WH), harness side. - Is the voltage greater than 10 volts? Yes GO to AE8. No REPAIR circuit GD138 (BK/WH) for an open. TEST the system for normal operation. ------------------------------------------------- AE8 CHECK THE TBC MODULE OUTPUT CIRCUIT FOR A SHORT TO GROUND - Measure the resistance between the TBC module C2142-3, circuit CAT19 (BU), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to AE9. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8996 No REPAIR circuit CAT19 (BU) fro a short to ground. TEST the system for normal operation. ------------------------------------------------- AE9 CHECK THE TRAILER ELECTRIC BRAKE CONTROLLER OUTPUT CIRCUIT FOR AN OPEN - Connect a fused jumper wire between the TBC module C2142-1, circuit SBB18 (YE/RD), harness side and the TBC module C2142-3, circuit CAT19 (BU), harness side. - Measure the voltage between the trailer tow C4099-3, circuit CAT19 (BU), harness side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the jumper wire. INSTALL a new TBC module. TEST the system for normal operation. No REMOVE the jumper wire. REPAIR circuit CAT19 (BU) for an open. TEST the system for normal operation. ------------------------------------------------- Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 9001 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 9002 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Right Turn > Page 9003 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 9006 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 9007 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 9008 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9014 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9015 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9016 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9017 Turn Signal Lamp: Diagrams Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9018 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9019 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9020 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9021 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9022 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9023 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9024 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9025 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9026 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 9030 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 9031 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 9032 Turn Signal Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 9033 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 9034 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left > Page 9039 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9045 Heated Glass Element Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9046 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9051 Heated Glass Element Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9052 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Quarter Window Open Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Quarter Window Open Relay > Page 9057 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 9060 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 9061 Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 9062 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch Power Window Switch: Locations Master Window Adjust Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9068 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9069 Power Window Switch: Locations Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9070 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9071 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9072 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9075 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9076 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9077 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9078 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9079 Power Window Switch: Diagrams Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9080 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (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 9083 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9084 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9085 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9086 Power Window Switch: Testing and Inspection Window Adjust Switches - Left Rear and Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9087 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 9088 Power Window Switch: Service and Repair Window Control Switch Removal and Installation NOTE: LF shown, all others similar. 1. Remove the door trim panel. 2. NOTE: There are 2 tabs on the opposite side not shown in the illustration. Unlock the 4 tabs and remove the window control switch from the door trim panel. 3. To install, reverse removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9095 Front Door Window Motor: Service and Repair Window Regulator Motor - Front Door Window Regulator Motor - Front Door Removal and Installation NOTE: The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Service and Repair. 1. Remove the front door trim panel. 2. Position the front door weathershield aside. 3. NOTE: Use a flat-blade screwdriver between the window regulator motor and window regulator assembly to hold the window regulator assembly drum in place. Remove the bolts and the front door window regulator motor. 1. Disconnect the electrical connector. 2. Remove the bolts. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. - Cycle the window glass to make sure the gears engage. - The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) window regulator is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component Information > Service and Repair Quarter Window Motor: Service and Repair Window Regulator Motor - Rear Quarter Removal 1. Remove the D-pillar trim panel. 2. Disconnect the rear quarter window regulator motor. - Remove the retaining clip. 3. Remove the bolts and rear quarter window regulator motor. - To install, tighten to 9 Nm (80 lb-in). - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9103 Rear Door Window Motor: Service and Repair Window Regulator Motor - Rear Door Window Regulator Motor - Rear Door Removal and Installation 1. Remove the rear door trim panel. 2. Position the rear door weathershield aside. 3. NOTE: Use a flat-blade screwdriver between the window regulator motor and the window regulator assembly to hold the window regulator assembly drum in place. Remove the rear door window regulator motor. 1. Disconnect the electrical connector. 2. Remove the bolts. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. - Cycle the door glass to make sure of gear engagement. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Quarter Window Open Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Quarter Window Open Relay > Page 9108 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 9111 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 9112 Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Close Relay > Page 9113 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch Power Window Switch: Locations Master Window Adjust Switch Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9118 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9119 Power Window Switch: Locations Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9120 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9121 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 9122 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9125 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9126 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9127 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9128 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9129 Power Window Switch: Diagrams Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9130 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9133 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9134 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9135 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9136 Power Window Switch: Testing and Inspection Window Adjust Switches - Left Rear and Right Rear Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9137 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 9138 Power Window Switch: Service and Repair Window Control Switch Removal and Installation NOTE: LF shown, all others similar. 1. Remove the door trim panel. 2. NOTE: There are 2 tabs on the opposite side not shown in the illustration. Unlock the 4 tabs and remove the window control switch from the door trim panel. 3. To install, reverse removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9145 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation NOTE: The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Service and Repair. 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 inside glass weatherstrip. 3. Remove the front door glass channel bolt and front door glass top run. - To install, tighten to 11 Nm (97 lb-in). 4. To install, reverse the removal procedure. - The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Window glass assembly 1. Remove the rear window wiper motor. 2. Disconnect the rear window defrost electrical connectors. 3. NOTICE: Do not extend the socket clips more than 2.0 mm (0.08 in) or failure of the socket can occur. NOTE: The liftgate glass must be supported when removing and installing the liftgate assist cylinders. Disconnect the 2 liftgate glass assist cylinders. 1. Insert a screwdriver blade under the socket clip and lift. 2. Gently pull the socket off the ball stud. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 9149 Window glass assembly or hinge assembly 4. Remove the liftgate glass hinge-to-body fasteners and remove the glass. - To install, tighten to 12 Nm (106 lb-in). Window hinge assembly 5. Remove the liftgate glass to hinge fasteners and remove the glass. - Apply threadlock to the liftgate glass-to-hinge fasteners during installation. - To install, tighten to 8 Nm (71 lb-in). Window glass assembly or window hinge assembly 6. To install, reverse the removal procedure. - Check the liftgate glass for high effort when closing. If high effort is present, adjust the striker one-half turn outboard. If high effort is still present, adjust the striker an additional one-half turn outboard. Do not exceed one full turn. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Removal All vehicles 1. Remove the rear quarter trim panel. 2. Remove the front and rear coat hooks and lower the headliner over the rear quarter window glass. Vehicles with power vent window 3. Remove the bolts and rear quarter window regulator motor. - Disconnect the electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 9153 4. Disconnect the rear quarter window regulator. All vehicles 5. Disconnect the audio antenna. 6. If equipped, remove the air duct. - Remove the pin-type retainer. 7. NOTE: Have an assistant hold the rear quarter window glass. Remove the rear quarter window glass. 1. Remove the nuts. 2. Remove the rear quarter window glass. 8. Remove the excess foam core butyl from the window opening. Installation All vehicles Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 9154 1. Apply 8 mm (0.32 in) foam core butyl to the rear quarter window glass frame. - Start at the bottom middle and work around the frame. 2. Install the rear quarter window glass. 1. Position the rear quarter window glass. 2. Install the rear quarter window glass nuts. - Tighten to 2 Nm (18 lb-in). 3. If equipped, install the air duct. - Install the pin-type retainer. 4. Connect the audio antenna. Vehicles with power vent windows 5. Install the rear quarter window regulator. 6. Install the bolts and rear quarter window regulator motor. - Tighten to 9 Nm (80 lb-in). - Connect the electrical connector. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 9155 All vehicles 7. Position the headliner and install the coat hooks. 8. Install the rear quarter trim panel. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 rear door glass channel bolt. - To install, tighten to 11 Nm (97 lb-in). 3. Remove the rear door glass top run. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9161 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9167 Front Door Window Regulator: Service and Repair Window Regulator - Front Door Window Regulator - Front Door Removal and Installation NOTE: The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Service and Repair. 1. Remove the front door trim panel. 2. NOTE: There are 2 tabs on the opposite side not shown in the illustration. Unlock the 4 tabs and remove the window control switch from the door trim panel. 3. Remove the screws and the front door speaker. - Disconnect the electrical connector. 4. Remove the front door weathershield. 5. Re-connect the electrical connectors to the window control switch. 6. Lower the window glass to access the 2 window glass clamp bolts. 7. Loosen the window glass clamp bolts. - To install, raise the window glass until it stalls in the UP position. Tighten the window glass clamp bolts to 11 Nm (97 lb-in). 8. NOTE: Secure the front window glass in the full UP position. Secure the front window glass with tape to the front door frame. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9168 9. Position the interior door handle aside. 1. Remove the cable conduit fitting from the carrier assembly. 2. Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. 3. Remove the cable from the door handle. 10. Release the crash sensor harness pin-type retainers. 11. Position the front door window regulator harness aside. 1. Disconnect the electrical connectors. 2. Release the pin-type retainers. 12. Remove the front window regulator. 1. Loosen the 2 hanger bolts. 2. Remove the front window regulator bolts and front top run channel bolt. - To install, tighten to 11 Nm (97 lb-in). Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9169 13. To install, reverse the removal procedure. - The power window regulator motor must be re-initialized whenever the LF/RF (Navigator) or LF (Expedition) window regulator is removed from the vehicle. For additional information, refer to Window Motor Initialization See: Service and Repair. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. For additional information, refer to the procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9174 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. NOTE: There are 2 tabs on the opposite side not shown in the illustration. NOTE: LF shown, LR and RR are similar. Unlock the 4 tabs and remove the window control switch from the door trim panel. 3. Remove the rear door speaker. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the speaker. 4. Remove the rear door weathershield. 5. Connect the window control switch. 6. Lower the window glass to access the window glass clamp bolts. 7. Disconnect the window control switch. 8. Loosen the window glass clamp bolts and remove the rear door window glass. - To install, tighten to 11 Nm (97 lb-in). 9. NOTE: Secure the rear window glass in the full UP position. Secure the rear window glass with tape to the rear door frame. 10. Disconnect the rear door window regulator electrical connectors. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 9175 11. Position the interior door handle aside. - Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. 12. Remove the rear door window regulator assembly. - Remove the bolts. - To install, tighten to 11 Nm (97 lb-in). 13. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass Windshield: Service and Repair Windshield Glass Windshield Glass Removal NOTE: If the windshield glass is being removed to repair a dust/water leak, remove and reinstall the existing windshield glass. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 9180 1. Remove the cowl panel grille. 2. Remove the A-pillar trim panels. 3. If equipped, remove the overhead console. 4. If equipped, remove the rain sensor. 5. Remove the interior rear view mirror. 6. Remove the sun visors. 7. Lower the front portion of the headliner. 8. Remove the windshield side mouldings. - Pull out starting at the top corner. 9. Remove the upper windshield weatherstrip. - Pull out starting at the corner. 10. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting the urethane adhesive. 11. 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. 12. NOTE: Refer to manufacturer's instructions before using the Deluxe Windshield Removal Tool. Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting the urethane adhesive. 13. 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: Support the windshield glass as necessary to prevent the glass from dropping while cutting the urethane adhesive. Insert the Deluxe Windshield Removal Tool at the upper center of the windshield glass and work toward the bottom corners. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 9181 14. Using The Pumper, distance the windshield from the body. 15. Insert the Deluxe Windshield Removal Tool into the bottom of the urethane adhesive and cut from corner to corner. 16. NOTE: Removing the windshield glass requires more than one technician. Carefully remove the windshield glass from the vehicle and place on a stable work surface. Installation 1. Dry-fit the 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. - Adjust the windshield glass stop blocks (if equipped) as needed for best fit. - Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass stop blocks) on the windshield glass and the body. 2. After the dry-fit alignment, remove the windshield glass 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 1-2 mm (0.04-0.8 in) base or 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 windshield removal. 5. If reinstalling the same windshield glass, remove any remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive bead. 6. 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. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 9182 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 windshield glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 8. Install the upper windshield weatherstrip. 9. Cut the urethane adhesive applicator tip to specification. 10. 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 just outside the foam butyl dam. - Make sure there are no gaps in the urethane adhesive 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 or water leaks. After the urethane adhesive has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 13. NOTE: Be sure the moldings seat completely. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 9183 Install the windshield side mouldings. 14. Install the headliner. 15. Install the interior rear view mirror. 16. If equipped, install the rain sensor. 17. Install the overhead console. 18. Install the A-pillar trim panels. 19. Install the sun visors. 20. Install the cowl panel grille. 21. Run the blower motor on defrost HIGH to check for glass that may have fallen into the defroster vents. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 9184 Windshield: Service and Repair Glass Reseal - Windshield Glass Reseal - Windshield 1. Remove the cowl panel grille. 2. Remove the A-pillar trim panels. 3. If equipped, remove the overhead console. 4. If equipped, remove the rain sensor. 5. If equipped, remove the roof opening panel trim. 6. Remove the interior rear view mirror. 7. Remove the sun visors. 8. Partially lower the front portion of the headliner near the windshield upper opening and block with a suitable material. 9. Clean the edge formed by the existing urethane adhesive and the glass on the inside at the top and sides, and outside on the bottom of the windshield with glass cleaner. 10. Cut the urethane adhesive applicator tip to specification. 11. 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. Apply a bead of urethane adhesive to the cleaned area. 12. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead. Backfill the urethane application and clean the excess. 13. 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. 14. Reposition the headliner. 15. Install the sun visors. 16. Install the interior rear view mirror. 17. If equipped, install the roof opening panel trim. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 9185 18. If equipped, install the rain sensor. 19. If equipped, install the overhead console. 20. Install the A-pillar trim panels. 21. Install the cowl panel grille. 22. Clean the interior and exterior of the windshield glass with glass cleaner. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Customer Interest for Rain Sensor: > 09-24-13 > Dec > 09 > Wipers/Washers - Rain Sensor Detached From Windshield Rain Sensor: Customer Interest Wipers/Washers - Rain Sensor Detached From Windshield TSB 09-24-13 12/14/09 RAIN SENSOR MOUNTING RING DETACHED FROM WINDSHIELD FORD: 2010 Taurus 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 MKS 2010 MKZ 2009-2010 Navigator 2010 MKT ISSUE Some 2009-2010 F-150 Platinum, Expedition, Navigator, MKS and 2010 Taurus, MKT and MKZ vehicles equipped with Rain Sensing Windshield Wipers may exhibit a detached rain sensor mounting ring. The rain sensor mounting ring is attached to the inside of the windshield near the rear view mirror. The windshield wipers will continue to function in manual mode, only the rain sensor feature is affected. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A service repair kit has been made available to resolve this issue. Order the Rain Sensor Repair Kit and follow the instruction sheet contained with this kit to resolve a detached rain sensor mounting ring. NOTE THE KIT REQUIRES CHEMICALS WHICH ARE NOT INCLUDED IN THE KIT. THESE CHEMICALS HAVE A SHORT SHELF LIFE AND ARE REQUIRED TO BE OBTAINED DIRECTLY FROM A SOURCE LISTED IN THE INSTRUCTION SHEET. 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 MT092413 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 17D596 33 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rain Sensor: > 09-24-13 > Dec > 09 > Wipers/Washers - Rain Sensor Detached From Windshield Rain Sensor: All Technical Service Bulletins Wipers/Washers - Rain Sensor Detached From Windshield TSB 09-24-13 12/14/09 RAIN SENSOR MOUNTING RING DETACHED FROM WINDSHIELD FORD: 2010 Taurus 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 MKS 2010 MKZ 2009-2010 Navigator 2010 MKT ISSUE Some 2009-2010 F-150 Platinum, Expedition, Navigator, MKS and 2010 Taurus, MKT and MKZ vehicles equipped with Rain Sensing Windshield Wipers may exhibit a detached rain sensor mounting ring. The rain sensor mounting ring is attached to the inside of the windshield near the rear view mirror. The windshield wipers will continue to function in manual mode, only the rain sensor feature is affected. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A service repair kit has been made available to resolve this issue. Order the Rain Sensor Repair Kit and follow the instruction sheet contained with this kit to resolve a detached rain sensor mounting ring. NOTE THE KIT REQUIRES CHEMICALS WHICH ARE NOT INCLUDED IN THE KIT. THESE CHEMICALS HAVE A SHORT SHELF LIFE AND ARE REQUIRED TO BE OBTAINED DIRECTLY FROM A SOURCE LISTED IN THE INSTRUCTION SHEET. 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 MT092413 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 17D596 33 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 9200 Rain Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 9201 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 9202 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 9203 Rain Sensor: Service and Repair Rain Sensor Removal and Installation 1. Pull outward on the rain sensor cover to remove. 2. Disconnect the rain sensor electrical connector. 3. NOTE: Prior to releasing the rain sensor retaining clips, it is necessary to apply light inward pressure at the bend of the retaining clips. Using a suitable screwdriver, release the 2 rain sensor retaining clips from the windshield mounted bracket and remove the rain sensor. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9208 Wiper Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9209 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Customer Interest for Rain Sensor: > 09-24-13 > Dec > 09 > Wipers/Washers - Rain Sensor Detached From Windshield Rain Sensor: Customer Interest Wipers/Washers - Rain Sensor Detached From Windshield TSB 09-24-13 12/14/09 RAIN SENSOR MOUNTING RING DETACHED FROM WINDSHIELD FORD: 2010 Taurus 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 MKS 2010 MKZ 2009-2010 Navigator 2010 MKT ISSUE Some 2009-2010 F-150 Platinum, Expedition, Navigator, MKS and 2010 Taurus, MKT and MKZ vehicles equipped with Rain Sensing Windshield Wipers may exhibit a detached rain sensor mounting ring. The rain sensor mounting ring is attached to the inside of the windshield near the rear view mirror. The windshield wipers will continue to function in manual mode, only the rain sensor feature is affected. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A service repair kit has been made available to resolve this issue. Order the Rain Sensor Repair Kit and follow the instruction sheet contained with this kit to resolve a detached rain sensor mounting ring. NOTE THE KIT REQUIRES CHEMICALS WHICH ARE NOT INCLUDED IN THE KIT. THESE CHEMICALS HAVE A SHORT SHELF LIFE AND ARE REQUIRED TO BE OBTAINED DIRECTLY FROM A SOURCE LISTED IN THE INSTRUCTION SHEET. 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 MT092413 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 17D596 33 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rain Sensor: > 09-24-13 > Dec > 09 > Wipers/Washers - Rain Sensor Detached From Windshield Rain Sensor: All Technical Service Bulletins Wipers/Washers - Rain Sensor Detached From Windshield TSB 09-24-13 12/14/09 RAIN SENSOR MOUNTING RING DETACHED FROM WINDSHIELD FORD: 2010 Taurus 2009-2010 Expedition, F-150 LINCOLN: 2009-2010 MKS 2010 MKZ 2009-2010 Navigator 2010 MKT ISSUE Some 2009-2010 F-150 Platinum, Expedition, Navigator, MKS and 2010 Taurus, MKT and MKZ vehicles equipped with Rain Sensing Windshield Wipers may exhibit a detached rain sensor mounting ring. The rain sensor mounting ring is attached to the inside of the windshield near the rear view mirror. The windshield wipers will continue to function in manual mode, only the rain sensor feature is affected. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A service repair kit has been made available to resolve this issue. Order the Rain Sensor Repair Kit and follow the instruction sheet contained with this kit to resolve a detached rain sensor mounting ring. NOTE THE KIT REQUIRES CHEMICALS WHICH ARE NOT INCLUDED IN THE KIT. THESE CHEMICALS HAVE A SHORT SHELF LIFE AND ARE REQUIRED TO BE OBTAINED DIRECTLY FROM A SOURCE LISTED IN THE INSTRUCTION SHEET. 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 MT092413 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 17D596 33 Disclaimer Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 9224 Rain Sensor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 9225 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 9226 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Technical Service Bulletins > Page 9227 Rain Sensor: Service and Repair Rain Sensor Removal and Installation 1. Pull outward on the rain sensor cover to remove. 2. Disconnect the rain sensor electrical connector. 3. NOTE: Prior to releasing the rain sensor retaining clips, it is necessary to apply light inward pressure at the bend of the retaining clips. Using a suitable screwdriver, release the 2 rain sensor retaining clips from the windshield mounted bracket and remove the rain sensor. 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9231 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9232 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9236 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9237 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9238 Windshield Washer Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9239 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9240 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9241 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9245 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9246 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9247 Wiper Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9248 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9249 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9250 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9254 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9255 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations Windshield Washer Motor: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 9259 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 9260 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. Failure to follow these instructions may result in serious personal injury. NOTICE: When servicing the windshield washer pump, be careful not to damage the windshield washer pump seal. NOTICE: Do not operate the windshield washer pump before filling the windshield washer reservoir. Failure to do so may result in premature pump failure. 1. Remove the RH headlamp assembly. 2. Position aside the shield as necessary to gain access to the washer pump. 3. Disconnect the windshield washer reservoir hoses. 4. Disconnect the windshield washer pump electrical connector. 5. Remove the windshield washer pump. 6. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. Failure to follow these instructions may result in serious personal injury. NOTICE: When servicing the windshield washer pump, be careful not to damage the windshield washer pump seal. NOTICE: Do not operate the windshield pump before filling the windshield washer reservoir. Failure to do so may result in premature pump failure. NOTE: The washer reservoir is integrated with the battery tray and cannot be serviced separately. 1. Remove the vehicle battery. 2. Drain the cooling system. 3. Disconnect the upper radiator hose at the radiator inlet, and position aside. 4. Remove the 3 battery tray bolts. - To install, tighten to 17 Nm (150 lb-in). 5. Carefully position the washer reservoir assembly to gain access to the electrical connectors and washer hoses. 6. Disconnect the windshield washer solvent level electrical connector, washer pump electrical connectors and washer hoses. 7. NOTE: If necessary, drain the windshield washer reservoir after removal. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 9267 Remove the washer reservoir assembly. 8. Transfer components as necessary. 9. To install, reverse the removal procedure. - Refer to Cooling System for coolant filling and bleeding procedures. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9271 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9272 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9273 Windshield Washer Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9274 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9275 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9276 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Power tilt column shown, manual tilt similar. Removal and Installation 1. Remove the steering column shroud. 2. Disconnect the 2 multifunction switch electrical connectors. 3. Remove the 2 screws and the multifunction switch. - To install, tighten to 1 Nm (9 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Wiper Blade and Pivot Arm Adjustment - Windshield Wiper Arm: Adjustments Wiper Blade and Pivot Arm Adjustment - Windshield Wiper Blade and Pivot Arm Adjustment - Windshield 1. Cycle and park the windshield wipers. 2. Verify the distance between the outer tip of the (1) RH windshield wiper blade and the (3) edge of the cowl panel grille and between the outer tip of the (2) LH windshield wiper blade and the (3) edge of the cowl panel grille are within specifications. 3. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. For additional information, refer to Wiper Pivot Arm - Front See: Service and Repair/Wiper Pivot Arm - Front. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Wiper Blade and Pivot Arm Adjustment - Windshield > Page 9281 Wiper Arm: Adjustments Wiper Blade and Pivot Arm Adjustment - Rear Wiper Blade and Pivot Arm Adjustment - Rear 1. Cycle and park the rear window wiper pivot arm and blade. 2. Check the rear window wiper park measurement. If not within specification, remove the rear window wiper pivot arm and reposition to the correct location. For additional information, refer to Wiper Pivot Arm - Rear See: Service and Repair/Wiper Pivot Arm - Rear. Ford Expedition 2wd Workshop Manual (V8-5.4L (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 Removal and Installation NOTICE: To prevent damage to the wiper pivot arm shaft splines, do not rotate the pivot arms into position manually. NOTE: The windshield wiper pivot arms must be in the highest position to remove them. 1. Turn the ignition switch to the ON position. 2. Turn the windshield wiper on. 3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch OFF. 4. Remove the windshield wiper pivot arm. - Remove the pivot arm nut cover. - Remove the nut. - Using a suitable 2-leg puller, remove the windshield wiper pivot arm. - To install, tighten to 35 Nm (26 lb-ft). 5. NOTE: Make sure the wiper motor is in the PARK position before installation of the wiper pivot arms. To install, reverse the removal procedure. - Adjust the windshield wiper pivot arms. For additional information, refer to Wiper Blade and Pivot Arm Adjustment - Windshield See: Adjustments/Wiper Blade and Pivot Arm Adjustment Windshield. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9284 Wiper Arm: Service and Repair Wiper Pivot Arm - Rear Wiper Pivot Arm - Rear Removal and Installation 1. NOTICE: Use a shop towel or similar device to protect the vehicle finish when carrying out the procedure. Remove the rear window wiper pivot arm. - Lift the pivot arm nut cover. - Remove the nut. - Using a suitable 2-leg gear puller, remove the rear window wiper pivot arm. - To install, tighten the nut to 12 Nm (106 lb-in). 2. NOTE: This step makes sure that the wiper motor is in the PARK position. Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the rear window wiper switch to OFF. 3. To install, reverse the removal procedure. - Adjust the rear wiper pivot arm. For additional information, refer to Wiper Blade and Pivot Arm Adjustment - Rear See: Adjustments/Wiper Blade and Pivot Arm Adjustment - Rear. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9285 Wiper Arm: Service and Repair Wiper Mounting Arm and Pivot Shaft - Windshield Wiper Mounting Arm and Pivot Shaft - Windshield Removal and Installation NOTICE: To prevent damage to the wiper pivot arm shaft splines, do not rotate the pivot arms into position manually. NOTE: The windshield wiper pivot arms must be in the highest position on the windshield before they are removed in order for the wiper mounting arm and pivot shaft assembly to be removed from the vehicle. 1. Remove the cowl grille panel. 2. Disconnect and position the hood light harness aside. 3. NOTICE: To prevent damage to the windshield glass and hood painted surfaces, make sure to protect the vehicle components using a shop towel or similar device when carrying out this step. With the aid of an assistant, remove the hood struts. - Using a suitable method, carefully support the hood in close proximity to the windshield glass. 4. Remove the mounting arm and pivot shaft assembly. 1. Disconnect the electrical connector and position the wiring harness aside. 2. Remove the bolts. - To install, tighten to 8 Nm (71 lb-in). 5. NOTE: If installing a new wiper mounting arm and pivot shaft assembly or windshield wiper motor, it will be necessary to temporarily connect the wiper motor electrical connector to operate the motor until the wiper motor crank has rotated approximately 180 degrees from the PARK position (as shipped). To install, reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9286 Wiper Arm: Service and Repair Striker and Wiper Pivot Shaft Assembly - Rear Striker and Wiper Pivot Shaft Assembly - Rear Removal 1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear See: Wiper Pivot Arm - Rear. 2. Remove the dust boot cover. 3. Remove the nut and the rear window glass handle. 4. Remove the nuts and the rear window striker and wiper pivot shaft assembly. Installation 1. Remove the liftgate trim panel. 2. NOTE: An audible click should be heard as the striker engages the latch. Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft pin should be aligned with the hole in the motor disc. 3. Install the rear window wiper motor alignment tool (2L1Z-14A163-AB). If installing a new rear wiper motor, one is provided with the motor assembly. 1. Make sure the alignment tool fits over the motor disc and striker assembly. 2. Make sure the alignment tool clips are securely engaged. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9287 4. Carefully close the liftgate glass. 5. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly nuts. Tighten to 6 Nm (53 lb-in). 6. Remove the rear window wiper motor alignment tool. 7. Close the liftgate. 8. Install the rear window wiper pivot shaft nut and handle. Tighten to 18 Nm (159 lb-in). 9. Install the dust boot cover. 10. NOTE: This step makes sure that the wiper motor is in the PARK position. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9288 Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the rear window wiper switch to OFF. 11. Install the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear See: Wiper Pivot Arm - Rear. 12. Open the liftgate. 13. Install the liftgate trim panel. 14. Test the liftgate and liftgate glass for normal operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9289 Wiper Arm: Service and Repair Wiper Mounting Arm and Pivot Shaft - Rear Wiper Mounting Arm and Pivot Shaft - Rear Removal and Installation 1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear See: Wiper Pivot Arm - Rear. 2. Remove the dust boot cover. 3. Remove the nut and the rear window glass handle. - To install, tighten to 18 Nm (159 lb-in). 4. Open the liftgate glass. 5. Remove the nuts and the rear window wiper striker and wiper pivot shaft assembly. - To install, tighten to 6 Nm (53 lb-in). 6. To install reverse the removal procedure. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor Assembly Wiper Motor: Locations Windshield Wiper Motor Assembly Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor Assembly > Page 9294 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor Assembly > Page 9295 Wiper Motor: Locations Rear Wiper Motor Assembly Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor Assembly > Page 9296 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor Assembly Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor Assembly > Page 9299 Ford Expedition 2wd Workshop Manual (V8-5.4L (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 1. Remove the mounting arm and pivot shaft. For additional information, refer to Wiper Mounting Arm and Pivot Shaft - Windshield See: Wiper Arm/Service and Repair/Wiper Mounting Arm and Pivot Shaft - Windshield. 2. Remove the windshield wiper motor crank from the motor assembly. - Remove the windshield wiper motor crank nut. - Using a suitable 2-leg puller, remove the wiper motor crank from the wiper motor shaft. 3. Remove the 3 windshield wiper motor bolts and the wiper motor. Installation 1. Install the windshield wiper motor to the wiper mounting arm and pivot shaft assembly. - Install the 3 windshield wiper motor bolts and tighten to 15 Nm (133 lb-in). 2. NOTICE: A new wiper motor is shipped in the PARK position. It is important the new wiper motor shaft position is not disturbed until the wiper motor crank arm is installed in the following steps. Failure to follow these instructions may result in the wiper arms not parking correctly when installed into the vehicle. Install the supplied template (part of 17504) to the wiper mounting arm bracket as shown. 3. NOTE: The alignment marks will allow the crank to be installed correctly in the PARK position. Using the alignment marks on the template, install the wiper motor crank arm to the wiper motor shaft. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 9302 4. NOTE: Make sure the wiper motor crank-to-wiper motor shaft alignment is not lost while tightening the wiper motor crank nut. Using an adjustable wrench as shown to prevent movement of the wiper motor crank, install the windshield wiper motor crank nut and tighten to 29 Nm (21 lb-ft). - Remove the template and discard. 5. Install the mounting arm and pivot shaft. For additional information, refer to Wiper Mounting Arm and Pivot Shaft - Windshield See: Wiper Arm/Service and Repair/Wiper Mounting Arm and Pivot Shaft - Windshield. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 9303 Wiper Motor: Service and Repair Wiper Motor - Rear Window Wiper Motor - Rear Window Removal 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 dust boot cover. 3. Remove the nut and the rear window glass handle. 4. Open the liftgate glass. 5. Remove the nuts and the rear window striker and wiper pivot shaft assembly. 6. Remove the liftgate trim panel. 7. Close the liftgate. 8. If installing a new rear wiper motor, remove the liftgate window glass latch. 1. Disconnect the electrical connector. 2. Remove the bolts. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 9304 9. Remove the rear window wiper motor. 1. Disconnect the electrical connector. 2. Remove the bolts. Installation 1. If installing a new rear wiper motor, install the liftgate window glass latch. 1. Tighten bolts to 8 Nm (71 lb-in). 2. NOTE: An audible click should be heard as the striker engages the latch. Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft pin should be aligned with the hole in the motor disc. 3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is provided with the motor assembly. 1. Make sure the alignment tool fits over the motor disc and striker assembly. 2. Make sure the alignment tool clips are securely engaged. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 9305 4. Install the rear wiper motor. 1. Tighten the bolts to 11 Nm (97 lb-in). 2. Connect the electrical connectors. 5. Carefully close the liftgate glass. 6. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly nuts. - Tighten to 6 Nm (53 lb-in). 7. Close the liftgate. 8. Install the rear window glass handle and nut.. - Tighten to 18 Nm (159 lb-in). 9. Install the dust boot cover. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 9306 10. Install the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear See: Wiper Arm/Service and Repair/Wiper Pivot Arm - Rear. 11. Open the liftgate. 12. Remove the rear window wiper motor aligning tool. 13. Open the liftgate glass. 14. Install the liftgate trim panel. 15. Test the liftgate and liftgate glass for normal operation. Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9310 Wiper Relay: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9311 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9315 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9316 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9317 Wiper Switch: Testing and Inspection Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9318 Ford Expedition 2wd Workshop Manual (V8-5.4L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9319